Best Practice in Advanced Manufacturing for Lightweight Structures

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1 CLUSTER OF EXCELLENCE MERGE Merge Technologies for Multifunctional Lightweight Structures EXC 1075 Best Practice in Advanced Manufacturing for Lightweight Structures Univ.-Prof. Dr.-Ing. habil. Prof. E. h. Prof. Lothar Kroll Coordinator Cluster of Excellence MERGE October 2017, Chemnitz, Germany

2 Cluster of Excellence MERGE MERGE Technologies for Multifunctional Lightweight Structures Research Cluster within the German Excellence Initiative 2rd Call Saxony MERGE is one of two clusters in the field of mechanical and production engineering and the one and only in the field of lightweight structures 2Iwww.tu-chemnitz.de/MERGE

3 Mission General Problems increasing prices of energy and raw materials climatechange by greenhouse effext, global warming Requirements energy savings mass reduction Approach Merge Technologies Lightweight Structures Strategy Bivalent ResourceEfficiency 3Iwww.tu-chemnitz.de/MERGE

4 Focus Merging of key enabling technologies, which are already technically mature In-lineand in-situ technologies predestined for large-scale production Metal-intensive technologies Textile-/Plastic-based technologies Micro- and Nanosystems Integration 4Iwww.tu-chemnitz.de/MERGE

5 MERGE Advisory Boards Partners in Science and Industry 14 Institutes of the TU Chemnitz, 3 Institutes of the TU Dresden; 7 Faculties 3 Affiliated Institutes of the TU Chemnitz, 2 Fraunhofer Institutes, 1 Leibniz Institute Selected industry partners Selected scientific partners 5Iwww.tu-chemnitz.de/MERGE

6 Internationalisation Start of international projects Partner countries AMiCE Alliance for Advanced Manufacturing in Central Europe (Interreg Central Europe) 11 partners SYNERGY Synergy (Interreg Central Europe) 7 partners TUC Sharing Strategies for European Research and Innovation Infrastructures (Interreg Europe) 8partners 6Iwww.tu-chemnitz.de/MERGE

7 European Lightweighting Clusters Alliance ELCA 14 European cluster joined forces representing more than one thousand companies Co-founder and coordinator is MERGE 7Iwww.tu-chemnitz.de/MERGE

8 MERGEurope One research focus: 3D-Printing in cooperation with Breslau 8Iwww.tu-chemnitz.de/MERGE

9 Research Focus Processing Materials Competence in 3D-Printing Process Parameters for new Materials Optimisation of SLM Machine Components Heat Treatment and Post Processes Characterisation of Material Properties Development of SLM Design Rules (Economic Efficiency) AluminiumAlloys (AlSi10Mg, AlSi9Cu3, Special Alloys ) Titanium Alloys (Ti6Al4V, Ti5553, ) Nickel-base Alloys (Stainless-) Steel Alloys (17-4PH, 316L, ) Hybrid Alloys (Ti-Diamond, Al-Diamond, Ti-TiC, ) 9Iwww.tu-chemnitz.de/MERGE

10 Selected References Palatal Implant Grinding Tools Medical Technology Mechanical Engineering Aerospace Structural Component Automotive Hydraulic Valve Block 10 I

11 A380 Spoiler Servo Control Requirements Class 1 equipment of primary flight control System pressure: 5,000 psi Impulse fatigue: pulse cycles Project Part of TU Chemnitz SLM Process Development Design to Manufacture Rules Component Design Project Results Weight Reduction: 35% Performance: equal to Reference Component Flight Test: since March 2017 on MSN I

12 Contact: Univ.-Prof. Dr.-Ing. habil. Prof. E. h. Prof. Lothar Kroll Reichenhainer Str. 31/33 Phone: +49 (0) 371/ Room 104 Fax: +49 (0) 371/ Chemnitz Germany 12 I