Abstract
(Englisch)
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Additive manufacturing (AM) has the economic potential to complement conventional manufacturing processes, especially in the production of
complex, multi-material (MM) components. To exploit the full benefits of optimized lightweight structures, it is usually required to use multimaterials with different physical properties.
Still, multi-material combinations from conventional processes are not transferable to AM, due to residual stresses, cracks or thermal expansion
rates of the different materials. Furthermore, geometric shape and position tolerances, as well as recycling strategies for powder waste, postprocessed waste and the component itself are not yet defined.
Based on the 3D printing processes PBF-LB and DED, this project aims at the concurrent engineering of designing processable multi-material
optimized alloys, development of design concepts for multi-material structures with specific simulations for load cases and topology optimizations,
and an extensive process adaption. Alloy and process development will be aided by advanced integrated computational material engineering
approaches that combine thermodynamics, microstructure, and process simulations through machine-/active learning, resulting in shorter material
development cycles. For bulk and powder materials, recycling of multi-material components via innovative concepts will promote the sustainability
of multi-material additive manufacturing. This adaption will lead to increased process reliability and speed, enabling the dissemination of MM
manufacturing in AM for the entire industry.
The consortium brings a wide range of international expertise to the table, from materials research and digitization to the manufacture of multimaterial components. It consists of startups, research institutions and market leaders in additive manufacturing. Industrial end-users cover
automotive, aerospace and aeronautic applications with specific use cases.
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