New Materials and Processes for Transport Applications: Going Hybrid and Beyond

Lehmhus, Dirk; Hehl, Axel von; Hausmann, Joachim; Kayvantash, Kambiz; Alderliesten, R.C.; Hohe, Jörg

doi:10.1002/adem.201900056

Cited by 10 publications

(6 citation statements)

References 32 publications

(30 reference statements)

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“…In general, examples of either kind exist for arbitrary matrix material classes (polymers [4], metals [5], ceramics [6]). Beyond AM, more conventional manufacturing techniques like metal casting can be employed to generate multi-material structures via approaches like compound or hybrid casting [7,8], the latter transgressing the boundaries of material classes by combining metals and plastics by reversing the processing sequence already known from overmolding [9]. The motivation behind realizing multi-material structures may either be the improvement of functional or structural properties, or both.…”

Section: Multi-materials Manufacturing: Techniques and Motivationsmentioning

confidence: 99%

Putting Stiffness where it’s needed: Optimizing the Mechanical Response of Multi-Material Structures

et al. 2021

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Manufacturing processes are increasingly adapted to multi-material part production to facilitate lightweight design via improvement of structural performance. The difficulty lies in determining the optimum spatial distribution of the individual materials. Multi-Phase Topology Optimization (MPTO) achieves this aim via iterative, linear-elastic Finite Element (FE) simulations providing element- and part-level strain energy data under a given design load and using it to redistribute predefined material fractions to minimize total strain energy. The result us a part configuration offering maximum stiffness. The present study implements different material redistribution and optimization techniques and compares them in terms of optimization results and performance: Genetic algorithms are matched against simulated annealing, the latter with and without physics-based constraints. Both types employ partial randomization in generating new configurations to avoid settling into local rather than global minima of the objective function. This allows exploring a larger fraction of the full search space than accessed by classic gradient-based algorithms. Evaluation of the objective function depends on FE simulation, a computationally intensive task. Minimizing the required number of simulation runs is the task of the aforementioned constraints. The methodology is validated via a three point bending test scenario.

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Section: Multi-materials Manufacturing: Techniques and Motivationsmentioning

confidence: 99%

Putting Stiffness where it’s needed: Optimizing the Mechanical Response of Multi-Material Structures

et al. 2021

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“…The contemporary concreting industry has progressively moved away from cumbersome SHM tools and techniques (Zinno et al , 2019). Researchers are hence actively looking for innovative Industry 4.0 solutions for monitoring of structures with the use of smart materials and sensors (Lehmhus et al , 2019) efficiently and economically, where Industry 4.0 represents a coalescence of digital and automated technologies working in unison (Edwards et al , 2017). In terms of utilisation of digital techniques for monitoring of concrete members, a series of research in digital SHM is redefining the way that structures are monitored and maintained (Concepcion et al , 2017).…”

Section: Structural Health Monitoring Of Concrete Membersmentioning

confidence: 99%

Real-time structural health monitoring for concrete beams: a cost-effective ‘Industry 4.0’ solution using piezo sensors

Ghosh

Edwards

Hosseini

et al. 2020

IJBPA

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PurposeThis research paper adopts the fundamental tenets of advanced technologies in industry 4.0 to monitor the structural health of concrete beam members using cost-effective non-destructive technologies. In so doing, the work illustrates how a coalescence of low-cost digital technologies can seamlessly integrate to solve practical construction problems.Design/methodology/approachA mixed philosophies epistemological design is adopted to implement the empirical quantitative analysis of “real-time” data collected via sensor-based technologies streamed through a Raspberry Pi and uploaded onto a cloud-based system. Data was analysed using a hybrid approach that combined both vibration-characteristic-based method and linear variable differential transducers (LVDT).FindingsThe research utilises a novel digital research approach for accurately detecting and recording the localisation of structural cracks in concrete beams. This non-destructive low-cost approach was shown to perform with a high degree of accuracy and precision, as verified by the LVDT measurements. This research is testament to the fact that as technological advancements progress at an exponential rate, the cost of implementation continues to reduce to produce higher-accuracy “mass-market” solutions for industry practitioners.Originality/valueAccurate structural health monitoring of concrete structures necessitates expensive equipment, complex signal processing and skilled operator. The concrete industry is in dire need of a simple but reliable technique that can reduce the testing time, cost and complexity of maintenance of structures. This was the first experiment of its kind that seeks to develop an unconventional approach to solve the maintenance problem associated with concrete structures. This study merges industry 4.0 digital technologies with a novel low-cost and automated hybrid analysis for real-time structural health monitoring of concrete beams by fusing several multidisciplinary approaches into one integral technological configuration.

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“…However, in certain production scenarios, these temperature levels may be exceeded by a large margin. One example of this type is compound casting, in the course of which separately manufactured components are joined to and/or integrated in cast components by means of the casting process itself [ 1 , 2 ]. Compound casting processes as such have been used across a wide range of material combinations and casting processes.…”

Section: Introductionmentioning

confidence: 99%

High-Temperature Mechanical Properties of Stress-Relieved AlSi10Mg Produced via Laser Powder Bed Fusion Additive Manufacturing

et al. 2022

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The present study is dedicated to the evaluation of the mechanical properties of an additively manufactured (AM) aluminum alloy and their dependence on temperature and build orientation. Tensile test samples were produced from a standard AlSi10Mg alloy by means of the Laser Powder Bed Fusion (LPBF) or Laser Beam Melting (LBM) process at polar angles of 0°, 45° and 90°. Prior to testing, samples were stress-relieved on the build platform for 2 h at 350 °C. Tensile tests were performed at four temperature levels (room temperature (RT), 125, 250 and 450 °C). Results are compared to previously published data on AM materials with and without comparable heat treatment. To foster a deeper understanding of the obtained results, fracture surfaces were analyzed, and metallographic sections were prepared for microstructural evaluation and for additional hardness measurements. The study confirms the expected significant reduction of strength at elevated temperatures and specifically above 250 °C: Ultimate tensile strength (UTS) was found to be 280.2 MPa at RT, 162.8 MPa at 250 °C and 34.4 MPa at 450 °C for a polar angle of 0°. In parallel, elongation at failure increased from 6.4% via 15.6% to 26.5%. The influence of building orientation is clearly dominated by the temperature effect, with UTS values at RT for polar angles of 0° (vertical), 45° and 90° (horizontal) reaching 280.2, 272.0 and 265.9 MPa, respectively, which corresponds to a 5.1% deviation. The comparatively low room temperature strength of roughly 280 MPa is associated with stress relieving and agrees well with data from the literature. However, the complete breakdown of the cellular microstructure reported in other studies for treatments at similar or slightly lower temperatures is not fully confirmed by the metallographic investigations. The data provide a basis for the prediction of AM component response under the thermal and mechanical loads associated with high-pressure die casting (HPDC) and thus facilitate optimizing HPDC-based compound casting processes involving AM inserts.

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New Materials and Processes for Transport Applications: Going Hybrid and Beyond

Cited by 10 publications

References 32 publications

Putting Stiffness where it’s needed: Optimizing the Mechanical Response of Multi-Material Structures

Putting Stiffness where it’s needed: Optimizing the Mechanical Response of Multi-Material Structures

Real-time structural health monitoring for concrete beams: a cost-effective ‘Industry 4.0’ solution using piezo sensors

High-Temperature Mechanical Properties of Stress-Relieved AlSi10Mg Produced via Laser Powder Bed Fusion Additive Manufacturing

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