Metal additive technology allows to create objects with complex shape that are very difficult to produce by conventional technologies. An example of such component is a porous structure which is composed of periodical truss cells. This diploma thesis deals with the prediction of the mechanical properties of very small lattice structures made of additive manufacturing technology Selective Laser Melting. Using the proposed test specimens it was found that real dimensions of the trusses varies with size and orientation to the base platform. It was proposed and tested samples for rod tensile test made of SLM. Based on the real information about dimensions and mechanical properties of rods were predicted mechanical properties of lattice structures. A lot of mechanical tests were carried out to obtain the real mechanical properties. Test results and conclusions are described in the thesis.

The first part of the diploma thesis is focused on the analysis and evaluation of the current production of sipes by two SLM devices PXL and M2 Cusing, produced by Phenix Systems and Concept Laser companies. The samples of both machines went through the same manufacturing process and the same process of measurement and evaluation, in order to carry out comparison between individual machines. Geometric accuracy, surface roughness, mechanical properties, and material structure of the samples have been compared. For the sipes it was necessary to create a digital evaluation methodology of geometry. In the second part of the thesis, process parameters are selected on the basis of research and further their influence on surface roughness of manufactured sipes is analyzed.

This study presents results of selective laser melting (SLM), powder metallurgy (PM), and casting technologies applied for producing Ti–TiB composites from Ti–TiB₂ powder. Diffraction patterns and microstructural investigations reveal that chemical reaction occurred between Ti and TiB₂ during all the three processes, leading to the formation of Ti–TiB composites. The ultimate compressive strength of SLM-processed and cast samples are 1421 and 1434 MPa, respectively, whereas the ultimate compressive strengths of PM-processed 25%, 29%, and 36% porous samples are 510, 414, and 310 MPa, respectively. The Young’s moduli of porous composite samples are 70, 45, and 23 GPa for 25%, 29%, and 36% porosity levels, respectively, and are lower than those of SLM-processed (145 GPa) and cast (142 GPa) samples. Fracture analysis of the SLM-processed and cast samples shows shear fracture and microcracks across the samples, whereas failure of porous samples occurs due to porosities and weak bonds among particles.

Über die additive Fertigung, oftmals bezeichnet als 3D-Druck, lassen sich Bauteile nahezu beliebiger geometrischer Komplexität herstellen. Gleichzeitig lassen die Prozessrandbedingungen die direkte Einstellung der Mikrostruktur in den verwendeten metallischen Werkstoffen zu. Hieraus ergeben sich weitreichende Möglichkeiten bezüglich der Eigenschaftsoptimierung aktueller Hochleistungswerkstoffe.

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The goal of the present dissertation is to develop and apply novel and systematic data-driven optimization approaches that can efficiently optimize Additive Manufacturing (AM) systems with respect to targeted properties of final parts. The proposed approaches are capable of achieving sets of process parameters that result in the satisfactory level of part quality in an accelerated manner. First, an Accelerated Process Optimization (APO) methodology is developed to optimize an individual scalar property of parts. The APO leverages data from similar—but non-identical—prior studies to accelerate sequential experimentation for optimizing the AM system in the current study. Using Bayesian updating, the APO characterizes and updates the difference between prior and current experimental studies. The APO accounts for the differences in experimental conditions and utilizes prior data to facilitate the optimization procedure in the current study. The efficiency and robustness of the APO is tested against an extensive simulation studies and a real-world case study for optimizing relative density of stainless steel parts fabricated by a Selective Laser Melting (SLM) system. Then, we extend the idea behind the APO in order to handle multi-objective process optimization problems in which some of the characteristics of the AMabricated parts are uncorrelated. The proposed Multi-objective Process Optimization (m-APO) breaks down the master multi-objective optimization problem into a series of convex combinations of single-objective sub-problems. The m-APO maps and scales experimental data from previous sub-problems to guide remaining sub-problems that improve the solutions while reducing the number of experiments required. The robustness and efficiency of the m-APO is verified by conducting a series of challenging simulation studies and a real-world case study to minimize geometric inaccuracy of parts fabricated by a Fused Filament Fabrication () system. At the end, we apply the proposed m-APO to maximize the mechanical properties of AMabricated parts that show conflicting behavior in the optimal window, namely relative density and elongation-toailure. Numerical studies show that the m-APO can achieve the best trade-off among conflicting mechanical properties while significantly reducing the number of experimental runs compared with existing methods.

Nature develops several materials with remarkable functional properties composed of comparatively simple base substances. Biological materials are often composites, which optime the conformation to their function. On the other hand, synthetic materials are designed a priori, structuring them according to the performance to be achieved. 3D printing manufacturing is the most direct method for specific component production and earmarks the sample with material and geometry designed ad-hoc for a defined purpose, starting from a biomimetic approach to functional structures. The technique has the advantage of being quick, accurate, and with a limited waste of materials. The sample printing occurs through the deposition of material layer by layer. Furthermore, the material is often a composite, which matches the characteristics of components with different geometry and properties, achieving better mechanical and physical performances. This thesis analyses the mechanics of natural and custom-made composites: the spider body and the manufacturing of metallic and non-metallic graphene composites. The spider body is investigated in different sections of the exoskeleton and specifically the fangs. The study involves the mechanical characterization of the single components by the nanoindentation technique, with a special focus on the hardness and Young's modulus. The experimental results were mapped, purposing to present an accurate comparison of the mechanical properties of the spider body. The different stiffness of components is due to the tuning of the same basic material (the cuticle, i.e. mainly composed of chitin) for achieving different mechanical functions, which have improved the animal adaptation to specific evolutive requirements. The synthetic composites, suitable for 3D printing fabrication, are metallic and non-metallic matrices combined with carbon-based fillers. Non-metallic graphene composites are multiscale compounds. Specifically, the material is a blend of acrylonitrile-butadiene-styrene (ABS) matrix and different percentages of micro-carbon fibers (MCF). In the second step, nanoscale filler of carbon nanotubes (CNT) or graphene nanoplatelets (GNP) are added to the base mixture. The production process of composite materials followed a specific protocol for the optimal procedure and the machine parameters, as also foreseen in the literature. This method allowed the control over the percentages of the different materials to be adopted and ensured a homogeneous distribution of fillers in the plastic matrix. Multiscale compounds provide the basic materials for the extrusion of fused filaments, suitable for 3D printing of the samples. The composites were tested in the configuration of compression moulded sheets, as reference tests, and also in the corresponding 3D printed specimens. The addition of the micro-filler inside the ABS matrix caused a notable increment in stiffness and a slight increase in strength, with a significant reduction in deformation at the break. Concurrently, the addition of nanofillers was very effective in improving electrical conductivity compared to pure ABS and micro-composites, even at the lowest filler content. Composites with GNP as a nano-filler had a good impact on the stiffness of the materials, while the electrical conductivity of the composites is favoured by the presence of CNTs. Moreover, the extrusion of the filament and the print of fused filament fabrication led to the creation of voids within the structure, causing a significant loss of mechanical properties and a slight improvement in the electrical conductivity of the multiscale moulded composites. The final aim of this work is the identification of 3D-printed multiscale composites capable of the best matching of mechanical and electrical properties among the different compounds proposed. Since structures with metallic matrix and high mechanical performances are suitable for aerospace and automotive industry applications, metallic graphene composites are studied in the additive manufacturing sector. A comprehensive study of the mechanical and electrical properties of an innovative copper-graphene oxide composite (Cu-GO) was developed in collaboration with Fondazione E. Amaldi, in Rome. An extensive survey campaign on the working conditions was developed, leading to the definition of an optimal protocol of printing parameters for obtaining the samples with the highest density. The composite powders were prepared following two different routes to disperse the nanofiller into Cu matrix and, afterward, were processed by selective laser melting (SLM) technique. Analyses of the morphology, macroscopic and microscopic structure, and degree of oxidation of the printed samples were performed. Samples prepared followed the mechanical mixing procedure showed a better response to the 3D printing process in all tests. The mechanical characterization has instead provided a clear increase in the resistance of the material prepared with the ultrasonicated bath method, despite the greater porosity of specimens. The interesting comparison obtained between samples from different routes highlights the influence of powder preparation and working conditions on the printing results. We hope that the research could be useful to investigate in detail the potential applications suitable for composites in different technological fields and stimulate further comparative analysis.

This qualification work consist of 123 pages, 30 pictures, 13 tables, 61 references and 2 appendixes. Object – Additive manufacturing in metallurgy. Subject – Organizational, technical and economic relations arising in the manufacturing processes of products based on additive technologies. The main purpose is developing of recommendations for involving the additive technologies taken into account business processes’ changes and production activities’ reflections of economic models. Research objectives: 1 Studying the influence of additive technologies on economic development in Russia and abroad. Identifying the main application branches of manufacturing. 2 Determination the current trends in additive technologies’ progress. Characterization the main processes and specifications. 3 Creating strategic elements for implementing the additive technologies, making aspects of business processes and functional economic models. Scientific novelty lies in the forming the upgraded supply chain at the areas of internal and external environment, and working-out universal business model of companies’ activities in the case of involving the additive technologies. Investment projects were calculating for comparison between the SLM and EBM technologies. Indicators of investment attractiveness of these technologies are presented. A method has been developed that allows to assess the ability of companies to introduce additive technologies, which has an advisory nature. / Выпускная квалификационная работа магистранта содержит 123 с, 30 рис., 13 табл., 61 библиографический источник, 2 приложения. Объект исследования – аддитивные технологии в металлургии. Предмет исследования – организационно-технические и экономические отношения, возникающие в процессе изготовления изделий на основе аддитивных технологий. Целью диссертационной работы является разработка рекомендаций по внедрению аддитивных технологий в металлургическое производство с учетом изменений в бизнес-процессах и экономических моделях, отражающих производственную деятельность предприятий. Цель обусловила ряд следующих задач: 1 Изучить влияние аддитивных технологий на экономическое развитие в России и за рубежом, обозначить основные перспективы их применения в различных отраслях экономики. 2 Определить современные тенденции развития аддитивных технологий в металлургии, охарактеризовать основные технологические процессы и их параметры. 3 Разработать элементы стратегии внедрения аддитивных технологий с учетом изменения в бизнес-процессах и экономических моделях функционирования организаций. Дано описание процессов аддитивного производства. За основу были взяты наиболее изученные технологии – процессы SLM и EBM, применительно к производству изделий из сплава Ti-6Al-4V и его отечественного аналога, сплава ВТ6. Приведены аспекты влияния аддитивных технологий на изменения в цепочках поставок и бизнес-моделях функционирования организации. Произведены расчеты инвестиционных проектов представленных технологий аддитивного производства. Представлен механизм оценки возможности организации к внедрению аддитивных технологий, имеющий рекомендательный характер.

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