For establishing Selective Laser Melting (SLM) in production technology, an extensive knowledge about the transient physical effects during the manufacturing process is mandatory. In this regard, a high process stability for various alloys, e.g. tool steel 1.2709 (X3NiC-oMoTi 18-9-5), is realisable, if approaches for the virtual qualification of adequate process parameters by means of a numerical simulation based on the finite element analysis (FEA) are developed. Furthermore, specific methods to evaluate and quantify the resulting residual stresses and deformations due to the temperature gradient mechanism (TGM) are required. Hence, the presented work contains particular approaches using the FEA for the simulation of transient physical effects within the additive layer manufacturing (ALM) process. The investigations focus on coupled thermo-mechanical models incorporating specific boundary conditions and temperature dependant material properties to identify the heat impact on residual stresses and deformations. In order to evaluate the structural effects and simultaneously validate the simulation, analysis on residual stresses based on the neutron diffractometry as well as considerations concerning part deformations are presented.

Selective Laser Melting is utilized to build parts directly from CAD data. In this study layerwise monitoring of the temperature distribution is used to gather information about the process stability and the resulting part quality. The heat distribution varies with different kinds of parameters including scan vector length, laser power, layer thickness and inter-part distance in the job layout. By integration of an off-axis mounted uncooled thermal detector, the solidification as well as the layer deposition are monitored and evaluated. This enables the identification of hot spots in an early stage during the solidification process and helps to avoid process interrupts. Potential quality indicators are derived from spatially resolved measurement data and are correlated to the resulting part properties. A model of heat dissipation is presented based on the measurement of the material response for varying heat input. Current results show the feasibility of process surveillance by thermography for a limited section of the building platform in a commercial system.

A physical-chemical model is suggested, which is able to describe the enhanced discharge rate capability of lithium-ion cells by using laser-structured graphite anodes. Recently published test data of coin cells comprising unstructured and structured graphite anodes with LiNi 1/3 Co 1/3 Mn 1/3 O 2 cathodes is used for the presented purpose of modeling, simulation and validation. To minimize computational demand, a homogenized three-dimensional model of a representative hole structure is developed, accounting for charge and mass transport throughout the cell layers and one-dimensional diffusion within radial-symmetric particles. First, a standard pseudo-two-dimensional model is calibrated against rate capability test data of coin cells with unstructured anodes. The calibrated parameter set is transferred to the three-dimensional model in order to simulate the transient voltage response and the discharged capacity depending on the applied Crate. The simulation data shows excellent agreement with experimental data for both cell types. Three stages of rate capability enhancement are identified showing an improved relative capacity retention of 11−24% at 3C. Experimental and simulation data reveal a restricted Crate window, which can be positively affected by the structuring process, whereas both shape and pattern of the structuring process can be further optimized with the model.

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Within this paper we report on a lithium-ion battery with laser-structured graphite anodes, alleviating current drawbacks of lithiumion batteries such as the reduced discharge capacity at high Crates and the onset of lithium-plating during fast charging. These issues are intensified at low temperatures, as reaction and diffusion kinetics decelerate, which is why a focus of the presented work lies on low temperature performance. Electrochemical impedance spectroscopy was used to show a reduction in the impedances of cells with laser-structured anodes in comparison to their conventional counterparts. The discharge capacity retention at high Crates was enhanced by up to 27% compared to conventional cells, proving potential for high power applications. For the cells with laserstructured anodes, the onset of lithium-plating at 0°C was observed at higher charging Crates by analyzing the voltage relaxation after charging. At −15°C, a smaller amount of plated lithium was detected, even though lithium-plating could not be entirely avoided. Laser structuring also enabled shorter charging times, as the upper cutoff voltage was reached at a higher SOC. The results point out that laser structuring of the anode improves the fast charging capability of lithium-ion cells, especially under demanding operating conditions.

Additive manufacturing processes typically used for mechanical parts can be combined with enhanced technologies for electronics production to enable a highly flexible manufacturing of personalized 3D electronic devices. To illustrate different approaches for implementing electrical and electronic functionality, conductive paths and electronic components were embedded in a powder bed printed substrate using an enhanced 3D printer. In addition, a modified Aerosol Jet printing process and assembly technologies adapted from the technology of Molded Interconnect Devices were applied to print circuit patterns and to electrically interconnect components on the surface of the 3D substrates.

Lithium-ion batteries are widely used as energy storage devices due to their high energy density and versatile applicability. Key components of lithium-ion batteries are electrically isolated electrodes and a liquid electrolyte solution which enables ion transport between the electrodes. Laser structuring of electrodes is a promising approach to enhance the high-current capability of lithium-ion batteries by reducing cell internal resistances, as a larger contact area of the active material with the electrolyte solution is created. In the work described here, lithium-ion battery anodes were structured by locally ablating small fractions of the coating using femtosecond laser pulses with infrared wavelengths. A study on ablation characteristics depending on different process parameters such as laser fluence and repetition rate was performed. Special focus was on the ablation efficiency, enabling an optimized process design. The influence of the electrode composition was taken into account by studying the ablation behavior at a varying binder content. Evenly distributed micro holes were chosen in order to keep active material removal at a minimum. To evaluate the effect of structured graphite anodes on the electrochemical properties of lithium-ion batteries, test cells were manufactured and galvanostatically cycled at different current rates. Results show improvements in high-current performance which is expressed by an increased discharge capacity yield.