Subproject IMKF-AF

Process optimization of SLM for complex internal structures and specific material properties

AM is of great importance for Germany as an industrial location, as the technology has the potential to stop the migration of production facilities to low-wage countries. The reason for AM's great potential is the process principle based on the direct construction of the component from the material. The almost unlimited geometrical design freedom allows functional integration or load-related weight optimization.

Together with the companies KMS, CellCore and edmos, new high-performance tools for injection moulding applications are developed. The Chair of Additive Manufacturing at the TU Bergakademie Freiberg will use the SLM process to manufacture tool inserts for processing complex geometries and materials that are difficult to produce. In addition, the sub-projects of the participating project partners will be supported with the existing technical expertise and testing resources. These include, for example:

  • Cooperation with the project partner KMS for the pre-validation of alternative manufacturing processes and materials to optimize the manufacturing process and wear properties,
  • Support in the optimization of the manufacturing process with the project partners KMS and CellCore,
  • Support in the characterization of surface qualities with the project partner edmos,
  • Cross-subproject support in long-term experimental investigations on the effect of surface properties on the tendency to deposit in the venting and cooling structures, and
  • Use of available resources from other departments of the TU Bergakademie Freiberg.

In the course of this project, all requirements and necessary properties of the tools or tool inserts are defined in cooperation with the involved project partners. Based on this, the relevant process parameters for process control are identified and different metal alloys and their properties are compared. In a further step, a validation concept will be developed, which will make it possible to validate the requirements and properties clearly for model geometries. The development of the model geometry and the selection of suitable methods for characterization by measurement technology are the main focus of this process.

Using this validation concept, the influencing factors for the following points will be investigated and optimized:

  • Creation of highly filigree interior and exterior structures,
  • Generation of defined and reproducible microstructures with predictable thermal properties and
  • Generation and adjustment of defined surface qualities.

The contents of this sub-project are handled completely by the Chair of Additive Manufacturing at the TU Bergakademie Freiberg. Deviating from this, the experimental investigations on plasma electrolytic polishing will be carried out in cooperation with the Beckmann Institute for Technology Development e.V..

Work package 1

Research on influencing factors and process parameters of SLM

Work package 2

Research and studies on AM materials

Work package 3

Development and definition of suitable validation strategies

Work package 4

Optimization of SLM process parameters for filigree structures

Work package 5

Optimization of SLM process parameters for the generation of defined microstructures and thermal properties

Work package 6

Optimierung der Prozessparameter des SLM für Einstellung definierter Oberflächengüten

Work package 7

Production of an injection mould tool insert prototype using the SLM process

Work package 8

Concept for surface finishing using plasma electrolytic polishing

Work package 9

Investigations for building up on conventionally manufactured basic bodies