Technology:
The DED-Arc Plasma process is used at the Chair of Materials Engineering for Additive Manufacturing to produce high-quality components with high deposition rates through advanced process control. A key feature of this process is the capability for in-situ mixing, which enables the production of Functionally Graded Materials (FGMs) and Metal Matrix Composites (MMCs). Materials currently under investigation include aluminum alloys, steel alloys, copper alloys, nickel alloys, and metal matrix composites. Both forms of feedstock are supported — powder as well as wire.
Components:
- KUKA 6-axis robot
- KUKA 2-axis external positioner
- SBI plasma welding power source (wire/powder)
- Oerlikon Metco powder feeder
- SBI twin wire feeder
Technology:
The DED-Arc MIG process is based on the MIG welding process. At the Chair of Materials Engineering for Additive Manufacturing, the technology is employed using a Fronius CMT power source. Several advanced cooling and heat input control technologies are being investigated to address the challenges of the process. Materials currently under research include high-strength steel and aluminum alloys.
The Machine:
- KUKA 6-axis robot
- KUKA 2-axis external positioner
- Fronius CMT welding power source
- Additional EWM MIG welding power source
Technology:
The EBM machine JAM-5200EBM by JEOL is the first of its kind in Europe and sets new standards in the field of additive manufacturing through electron beam melting. It offers a unique combination of high precision, material efficiency, and productivity. The machine operates with a powerful electron beam capable of melting metals and building them up layer by layer, making it particularly suited for high-strength and temperature-resistant materials such as titanium alloys. Through the use of a high-vacuum system, oxidation-prone metals can be processed without any loss of quality. The JAM-5200EBM enables not only the production of complex components but also the reduction of production waste.
Technical Specifications:
| High-performance beam | maximum 6kW |
| Long-life cathode | 1,500 hours or longer |
| Electron beam correction | Automatic |
| Heating capacity | 1,100 °C or higher |
| Remote monitoring system | Yes |
| Powder scattering prevention system | e-Shield |
| Materials | Ti-6Al-4V, IN718, Cu |
| Build volume | Maximum 250 mm (diameter) × 400 mm (height) |
Technology:
The TruLaser Cell 7020 by Trumpf is a highly flexible 5-axis laser machine ideally suited for powder-based laser metal deposition (LMD) and laser welding. It is equipped with a GTV powder feeder featuring two powder hoppers, enabling in-situ alloying and thus the production of multi-material components. This offers a wide range of possibilities for combining materials in a targeted manner and manufacturing components with tailored properties. In addition, various deposition nozzles are available, including 3- and 4-beam nozzles as well as annular powder feed nozzles, ensuring precision and flexibility during processing.
Technical Specifications:
| Laser source | TruDisk 6002 |
| Laser power | 6 kW |
| Wavelength | 1,030 nm |
| Axis travel range | X/Y/Z = 2000/1000/750 mm |
| Control system | Sinumerik 840D |
| Process gas | Argon |
Short Description:
Ultrasonic Atomization (UA) is an innovative process for producing highly spherical metal powders. Unlike conventional gas atomization, it does not use high-velocity gases; instead, the liquid metal melt is atomized by high-frequency ultrasonic waves in an inert atmosphere. The UPA system rePowder by AMAZEMET enables the production of metal powder from virtually any alloy and starting form. The particle size distribution can be precisely controlled by adjusting the frequency and amplitude of the ultrasonic system. Alloy development is also possible, allowing the creation of entirely new metal powders tailored to specific applications.
Applications:
- Production of highly spherical powder in small quantities
- Recycling of failed prints, support structures, waste powder, and scrap
- Alloy development
Equipment:
- Plasma unit (up to 3,500 °C, 40 kHz):
- Mechanical vacuum gripper
- Rod feeding — continuous wire feeder
- Gas recirculation system and oxygen monitoring
- Induction unit (up to 1,300 °C, 40 kHz):
- Graphite crucibles of 225 cm³ and 400 cm³
- Atomization discs in various sizes and materials
Example Figures:
