Forum Aviation II

WEDNESDAY, 23 June 2021

Location: CongressCenter, ground floor, Room Carl Zeiss

Advice: You can export your favourite lectures directly into your personal calender. Choose the lecture by ticking the box on the right side and then click the download button on the top of the schedule. Please export only one date at a time. 

08:30 - 09:00
09:00 - 09:45

The aerospace industry is characterized by small quantities, the highest safety requirements and, more than almost any other industry, by the need to save weight. Every reduced kilogram of weight saves up to 3 kg of CO2 - and that on a daily basis. Moreover, the short-term supply of spare parts is quite challenging. That is why aerospace industry is ideal for the introduction of components that are topologically optimized and manufactured by 3D printing processes. For more than 10 years, parts have been converted from conventional design and manufacturing to additive processes. The results are clear: components become lighter, smaller and may even integrate more functions.

Nevertheless, the conversion process is progressing slowly. There are several reasons, starting first and foremost with the demand for maximum safety. With existing design and production processes, all necessary qualifications are available for the required safety of components. For 3D printing, unfortunately, we are still at the beginning and, therefore, invest a lot of time and energy in process qualifications. We have to ensure that the internal structures and the surfaces meet all the requirements for permanent, safe operations. In parallel, we are, of course, continuing to work on optimizing the processes, on new material combinations and design processes, because we are certain that 3D printing will be indispensable for the climate-neutral aircraft of the future.

Volker Thum | BDLI Bundesverband der Deutschen Luft- und Raumfahrtindustrie e.V.

Volker Thum

09:45 - 10:15
Coffee break & Visit to the exhibition
10:15 - 12:45
Forum "News from AM II" in the room Carl Zeiss
12:45 - 13:15
Lunch break and visit to the exhibition
Session 1
13:15 - 13:45

 Additive Manufacturing provides a unique design freedom for the manufacture of complex structural and functional components. Due to the low quantity of products that is typical for the space industry, AM shows promising applications for satellites.
In contrast to traditional manufacturing, for AM the material properties cannot be taken from a material database, since they are generated just during the process. Experience shows that the component quality depends on the raw material, the process parameters, the type of AM system and the individual component supplier. Thus, a robust and reliable process chain is essential to ensure the quality required for flight hardware.
The presentation highlights OHB's approach to implement satellite components using AM. The presented process focuses on the interaction between design and structural analysis using topological optimization. Recently developed components are presented to illustrate the advantages of the technology over conventional solutions. An outlook is given on material validation, process control and part verification for flight hardware.

Dr. Marco Mulser | OHB System AG



11:00 - 11:30

The production of large structures made of expensive metallic materials poses major logistical and economic challenges for the aerospace and other industries. Classical powder bed based additive manufacturing processes are hardly suitable for the economic production of large structures due to limited build space and the recycling of large quantities of metal powder.
For this reason, MT Aerospace is pursuing the two processes of Additive Friction Stir Welding and Directed Energy Deposition with the aim of producing both hybrid and fully additive components which meet the highest requirements in terms of process reliability and material properties.
The focus for Directed Energy Deposition is put on titanium alloys, while the Additive Friction Stir Welding process is mainly used for non-weldable aluminum alloys.
In addition to the classic advantages of additive manufacturing, such as shorter leadtimes and more degrees of freedom in product design, both processes offer further unique advantages that make both technologies very interesting for highly stressed large structures.
Directed Energy Deposition is highly scalable, regardless of the type of material feed, since the process nozzle itself can be implemented on different mechanical systems such as robots or gantry systems.
Due to the non-melting joining process, Additive Friction Stir Welding is ideally suited to weld alloys which classically are non-weldable or hybrid applications with excellent material properties.
Both processes as well as applications are presented.

Markus Axtner | MT Aerospace AG



14:15 - 14:45
Coffee break & Visit to the exhibition
Session 2
14:45 - 15:00

In the economy, the dynamic competitive environment is giving rise to an increasing urge for shorter product development times, high functional integration and individualized products. Here, additive manufacturing processes (AM) are gaining increasing industrial significance, as they are a key technology for future production due to their flexibility, the use of innovative materials and the sustainable production on a digital basis. In view of these challenges, individualized and complex products and new development processes are addressed as key topics.
As an approach to increase productivity, the combination with established manufacturing processes is used by defining suitable functional carriers of a component, i.e. single elements of a component, whose production obtains an added value by using additive manufacturing processes. Conventional manufacturing processes, on the other hand, are used where they remain more economical or where the scope of application cannot be covered by the conditions of industrial production by AM so far.
The presentation will present an integrative view of the entire hybrid AM process chain with post-processing and further processing by established productive manufacturing processes.
Furthermore, an examination of the energy and resource efficiency as well as the current standardization activities in the wider environment of such a "smart production", which includes the hybrid process chain, is presented. The focus here is on the manufacturing environment with the fundamentals across the entire value network.

Martin Schäfer | Siemens AG



15:00 - 15:15

Over the entire lifetime of an aircraft, sustainability and therefore energy and resource efficiency play a decisive role. This guiding principle must already be taken into account during the production of aircraft components. More than 60 percent of the semi-finished product is machined during conventional production and ensures increased raw material and energy consumption during manufacture.
This is where the concept of hybrid production using laser metal deposition with wire (additive) and machining (conventional) comes together. An additive build-up is carried out locally and flexibly on a semi-finished product as required. The dimensions of the semi-finished product can be made smaller. This leads to a reduction in the amount of material used, shorter machining times, significantly less tool abrasion and lower energy consumption already during production.
In the presentation, this concept will be presented using the example of an aircraft turbine housing, which was developed in the AGENT-3D project IMProVe, funded by the German Federal Ministry of Education and Research (BMBF) and in cooperation between MTU Aero Engines AG and the Fraunhofer Institute for Material and Beam Technology IWS.

Stefan Polenz | Fraunhofer-Institut für Werkstoff- und Strahltechnik IWS

Stefan Polenz studied Material Science at the Technische Universitaet Dresden. He is working as a scientist in the group of Direct Energy Deposition and Hybrid Manufacturing at the Additive Manufacturing Center Dresden (AMCD) at Fraunhofer Institute for Material and Beam Technology IWS. He is working on different scientific research projects. His current projects focus on hybrid manufacturing approaches, especially Additive Manufacturing (Laser Metal Deposition) and wavelength-dependent laser material interaction particularly regard to metallic compounds and ceramic matrix composites.

15:15 - 15:45

In recent years, additive manufacturing dominates research activities the material and process disciplines like no other modern manufacturing technology. In addition to the widespread activities by large corporations, a continuously growing interest among small and medium sized companies is observable. However, the latter often do not have the competence and resources to evaluate the strength potential and thus the reliability of AM structures. Corresponding experimental investigations are time-consuming and cost intensive. New methods are therefore required to estimate the mechanical load-bearing capacity of generated materials reliably, fast and economically.

The mechanical behavior of additively manufactured components is generally dominated by existing inhomogeneities and defects. The extent of the voids is directly linked to the quality of the raw material and the process routine. While this is only noticeable in case of significant quality defects for the static strength, even the smallest defects have a huge influence on the fatigue strength, especially in the costly and time-consuming area of the fatigue limit.

The present study focuses on the fatigue behavior of additively manufactures Ti6Al4V. The results illustrate the significant influence of the entire process routine on the material strength. A spatially resolved characterization of the correlation between process, structure and property is of particular importance. The potential of the high frequency fatigue testing as a time saving method for determining the fatigue strength of additively manufactured structures could be shown within the scope of the investigations.

Dr. Martina Zimmermann | Fraunhofer IWS

Professional & Scientific Career
2004 – 2012    Assistant Professor (Oberingenieurin) at the Institute of Material Science, University of Siegen
2009 - 2010    Visiting Research Scholar, Department of Materials Science, University of Michigan, Ann Arbor, USA
2012 – 2015    Group Leader: Materials Characterization and Testing, Fraunhofer Institute for Material and Beam Technology, Dresden
2012 – 2015    Professor of Material Testing and Characterization at the Technical University of Dresden
since 2015    Division Manager: Materials Characterization and Testing, Fraunhofer Institute for Material and Beam Technology, Dresden
since 2015    Professor of Mechanics of Materials and Failure Analysis at the Technical University of Dresden

Others (Selection)

since 2013    Tutor of the German Academic Scholarship Foundation
2014    Galileo Prize of the DGM, DVM and the VdEh for special merits in the field of material testing
since 2014    A member of a TUD selection committee for the gender specific Maria-Reiche foundation
since 2016    Deputy spokesperson for the review board “Materials Engineering” of the German Research Foundation
since 2021    President of the German Society for Materials Science

15:45 - 16:15

The Presentation highlights opportunities and challenges of incorporating AM technology on the Boeing 777X Folding Wingtip System Secondary Lock Actuator.

The Case Study shows how Liebherr addressed challenges like thermal stresses in production, pressure drops in operation, surface treatment and wear surfaces of titanium cylinders.
Furthermore, an outlook will be provided regarding the challenges of the technology and the implementation to serial production of highly integrated components.

Alexander Altmann | Liebherr-Aerospace Lindenberg GmbH

Get more information about the forum "Aviation I"?

Tuesday, 22 June 2021