An interdisciplinary research team is investigating how metal structures can be optimized for specific loads. This involves the use of laser metal deposition, an additive manufacturing process in which metals are built up layer by layer. The aim of the group led by Prof. Dr. Andreas Ostendorf from Ruhr University Bochum is to further develop the process with the help of robotics and computer simulations. Funded by the German Research Foundation with 3.85 million euros over four years, the project will begin at the start of 2025.
Laser cladding offers decisive advantages over conventional manufacturing methods such as casting or milling. While conventional processes often reach their geometric limits, laser metal deposition enables the production of complex free-form components. The surface of the metal is heated and melted locally by a laser beam, while a metal wire is inserted into the molten pool. The molten materials combine and the component is built up layer by layer.
Such components are particularly in demand in the aerospace industry and for special tools, as they have to withstand high loads and at the same time be as light as possible. Using computer simulations, the team calculates the optimum geometry and material distribution in advance in order to achieve maximum stability with minimum weight. These digital models serve as precise construction plans for the production process.
The implementation is carried out by two specialized robots. While the first robot builds the structure using laser deposition welding, the second robot takes over the milling to reduce the surface roughness and further refine the components. This combination of additive and subtractive manufacturing is being tested at the ZESS research center in Bochum. The results could be groundbreaking for industrial applications where precision and resilience are essential.
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