A 07

Wire and Arc Additive Manufacturing (WAAM) of Complex Individualized Steel Components

Prof. Dr.-Ing. Jonas Hensel, Project leader
Prof. Dr.-Ing. Harald Kloft, Project leader
Prof. Dr. sc. techn. Klaus Thiele, Project leader

Dr.-Ing. André Hälsig
M. Sc. Hendrik Jahns
M. Sc. Johanna Müller
Dipl.-Ing. Christoph Müller
M. Eng. Ronny Scharf-Wildenhain
Dr.-Ing. Julian Unglaub

Summary of A 07

Project A07 investigates structural design, WAAM methods and component tes- ting of complex, large-scale, individualized steel components. The objective is to connect conventionally manufactured steel components and semi-finished pro- ducts with additively manufactured, complex steel components (connection no- des, 3D steel inserts for concrete). The research programme is based on innovative design and manufacturing methodologies that take both additive manufacturing parameters and material properties into account. The evaluation of the WAAM components follows a novel test method, which considers potentially anisotropic component behaviour, surface topographies, geometric irregularities and residual stresses in addition to the relevant material properties.

Dr.-Ing. Jonas Hensel

is head of division Welding and Beam Technology at ifs and takes responsibility for the management of this project in terms of content and organisation as well as the cooperation with project partners within the SFB. Further, he supervises the research assistant of WG Hensel for welding experiments, metallographic char- acterisation, numerical analysis and residual stress determination.

j.hensel(at)tu-braunschweig.de

Prof. Dr.-Ing. Harald Kloft

leads the scientific staff in the orientation and execution of the design process creation and supports them in an advisory capacity in the creation of test geometries and demonstrators. He is responsible for the content and organisational coordination of all work on the part of WG Kloft.

ite(at)tu-bs.de

Prof. Dr. sc. techn. Klaus Thiele

is head of institute at IS. He coordinates all scientific and organisational work regarding testing and material modelling.

sekretariat(at)stahlbau.tu-braunschweig.de

M. Sc. Hendrik Jahns

doctoral researcher at IS. He is responsible for the planning and execution of all scientific work, both numerical and experimental, in the framework of WAAM. This includes material and component testing, material modeling, analysis all data, prepares reports, presentations and publications.

h.jahns(at)stahlbau.tu-braunschweig.de

Dipl.-Ing. Markus Köhler

markus.koehler(at)tu-braunschweig.de

M. Sc. Johanna Müller

is a doctoral researcher at ifs. She is responsible for the planning and execution of all scientific work, both numerical and experimental, in the framework of WAAM. This includes welding experiments, metal- lographic characterisation and material testing. She further analysis all data, prepares reports, presentations and publications.

johanna.mueller(at)tu-braunschweig.de

Dipl.-Ing. Christoph Müller

is a doctoral researcher for the duration of the research project carrying out the scientific studies. He will carry out the scientific studies: Design of WAAM components, creation of a design process for WAAM, creation of sample geometries.

christoph.mueller(at)tu-bs.de

Dr.-Ing. Julian Unglaub

is head of division Material behavior at IS and takes responsibility for management of this project in terms of content and organization. He supervises the research assistants of WG Thiele for novel material and component testing methods based on MultiCam Digital Image Correlation (DIC) and the development of complex material models to describe WAAM-component behavior.

j.unglaub(at)stahlbau.tu-braunschweig.de

2021 |Müller, J., Hensel, J., Dilger, K.: Schweißtechnische Verarbeitung von hochfestem Stahl als Aufbauwerkstoff beim Wire and Arc Additive Manufacturing, in: Fortschrittsberichte der Materialforschung und Werkstofftechnik / Bulletin of Materials Research and Engineering, Band 10, Clausthaler Zentrum für Materialtechnik (Hrsg.), Shaker Verlag Düren 2021 (ISBN: 978-3-8440-8021-6)2019 | Köhler, M.; Fiebig, S.; Hensel, J.; Dilger, K.: Wire and Arc Additive Manufacturing of Aluminum Components. In: Metals, vol. 9, no. 5, p. 608.doi: 10.3390/met9050608.

2019 | Müller, J.; Grabowski, M.; Müller, C.; Hensel, J.; Unglaub, J.; Kloft, H.; Thiele, K.; Dilger, K.: Design and parameter identification of Wire and Arc Additively Manufactured (WAAM) steel bars for use in construction” vol. 9, no. 7, p. 725. doi:10.3390/met9070725.

2019 | Sun, J.; Hensel, J.; Klassen, J.; Nitschke-Pagel, T.; Dilger, K.: Solidstate phase transformation and strain hardening on the residual stresses in S355 steel weldments. In: Journal of Materials Processing Technology, vol. 265, pp 173-184, doi: 10.1016/j.jmatprotec.2018.10.018.

2018 | Scholl, N.; Minuth-Hadi, F.; Thiele, K.: Modelling the Strain Rate Dependent Hardening of Constructional Steel using semi-empirical models. In: Journal of Constructional Steel Research, S. 414– 424. doi: 10.1016/j.jcsr.2018.02.013.

2018 | Gusella, F.; Orlando, M.; Vignoli, A.; Thiele, K.: Flexural capacity of steel rack connections via the component method. In: Open Construction and Building Technology Journal. doi: 10.2174/1874836801812010090.

2018 | Schork, B.; Kucharczyk, P.; Madia, M.; Zerbst, U.; Hensel, J.; Bernhard, J.; Tchuindjang, D.; Kaffenberger, M.; Oechsner, M.: The effect of the local and global weld geometry as well as material defects on crack initiation and fatigue strength. In: Engineering Fracture Mechanics, vol. 198, pp. 103-122, doi: 10.1016/j.engfracmech.2017.07.001.

2014 | Hensel, J.; Nitschke-Pagel, T.; Dilger, K.; Wimpory, R. C.: Residual Stresses in Welded Steels with Longitudinal Stiffeners Determined by Neutron and X-Ray Diffraction. In: International Journal of Offshore and Polar Engineering, vol. 24, no. 4, pp. 1–8 oder pp. 278-285, (ISSN 1053-5381).

2014 | Kloft, H.; Hoyer, S.: Zum Entwerfen von Tragwerken/On designing structures. In: Stahlbau, 83(11), pp. 806-814,. doi: 10.1002/stab.201410216.

2012 | Kloft, H.: Engineering of Freeform Architecture. In: Fabricating Architecture: Selected readings in digital design and manufacturing, R. Corser, (ED),Princeton Architectural Press; pp. 110- 127, isbn-13: 97815689888894.

Zerbst, U.; Madia, M.; Schork, B.; Hensel, J.; Kucharczyk, P.; Tchoffo Ngoula, D.; Tchuindjang, D.; Bernhard, J.; Beckmann, C.: Fatigue and Fracture of Weldments. In: Springer, Cham. doi: 10.1007/978-3- 030-04073-4.