A3 Material accumulation

Generation of functional parts of a component by laser-based free form heading

The project A3 material accumulation dealt with an alternative process chain for the production of preforms for forging and sheet metal forming. Laser rod end melting enables upset ratios >>200 instead of an upset ratio of approximately 2, which can be achieved using conventionally methods. The main objective in the 3rd phase was to decrease process cycle time for laser melting so that it can be applied in mass production. This was accomplished by using the keyhole effect to achieve high energy absorption. An extended finite element method was used to optimize the process parameters and heating strategies. In the calibration process in closed dies, the reproduction accuracy was investigated and positively influenced by a specific variation of the parameters of the master forming step.

Project term: 2007-2018