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If a manufacturer discontinues a certain component, this can mean that an otherwise fully functional machine can no longer be operated. Technically, therefore, the problem does not lie in the overall system, but in the lack of availability of a single mechanical element. The result is often that machines are shut down or replaced prematurely. This is problematic from an ecological point of view, as it again involves considerable material and energy costs for the manufacture, transportation and commissioning of a new system - even though the existing machine could often be used for years with a suitable replacement part.

With metallic 3D printing, especially in the PBF-LB process (the laser powder bed fusion/laser beam melting process widely used in industry), components that are no longer available can be digitally reconstructed and manufactured again as required. This is particularly relevant when traditional manufacturing processes reach their economic or logistical limits, for example in the case of small quantities or a lack of tools. An additional advantage is that we can not only reproduce existing geometries, but also use the geometric degrees of freedom of additive manufacturing for design purposes, for example through functionally integrated structures such as additional cooling channels. This means that a spare part can not only be reproduced, but ideally also functionally enhanced.

The real challenge is not to reduce additive manufacturing to pure geometry replication. The PBF-LB process is not just about producing a component with the same shape, but also about mastering the process and material side in such a way that the required properties are achieved in the end. On the one hand, this concerns the reverse engineering of existing components, but also the targeted use of additive design freedom, for example for more efficient designs or functionally integrated structures. At the same time, material development plays a central role - in our case, in particular the development of heat-resistant aluminum alloys for the PBF-LB process. Only the interplay of design, material and process control results in a component that is not only manufacturable but also resilient in real-life use.

In our project, we are developing heat-resistant aluminum alloy powders and mixed systems of pure and alloy powders to improve the heat resistance and hydrogen resistance of additively manufactured components. On this basis, we are investigating the production of hydrogen-carrying components, for example cylinder heads for hydrogen combustion engines, following corresponding parameter studies. The link to the circular economy lies in the fact that additive manufacturing is not only interesting for the development of new parts, but also for targeted obsolescence management. If existing engine concepts - for example by converting diesel engines to hydrogen combustion - can continue to be used instead of replacing entire systems, this is also relevant from a resource perspective. Additive manufacturing can help to provide the necessary components flexibly and close to the application.

Economics remains a key issue. Although the PBF-LB process offers advantages such as high material utilization and great design flexibility, its industrial implementation is still associated with workload. This applies in particular to powder handling under safety requirements and the often demanding post-processing steps. However, this is precisely where component quality and costs are often decisive. In order for such processes to become more widely accepted, not only must materials and process parameters be further developed, but the downstream process chains must also become more robust, efficient and economical. Technological advances are already showing that these hurdles are increasingly being reduced, but they are currently still a significant limiting factor.

Sebastian Gersch is a researcher at the Doctoral Center Engineering Sciences and Information Technologies at Anhalt University of Applied Sciences. The specific title of his doctoral thesis: "Investigation of the real potential of superposition effects from residual compressive stresses and resulting tensile stresses to optimize the fatigue strength of LPBF-manufactured single tooth geometries"

The project behind his doctoral thesis: "3DAlu: Development of heat-resistant aluminum alloy for 3D-printed components for hydrogen engines". This is associated with funding from the European Union and the state of Saxony-Anhalt as part of the ERDF program.

Find out more on the project page and our LinkedIn focus page Forschung.Transfer.Messen:

https://www.hs-anhalt.de/projekte/projekt/3dalu-entwicklung-von-warmfesten-aluminiumlegierung-fuer-3d-gedruckte-komponenten-fuer-wasserstoffmotoren-prof-dr-joerg-bagdahn.html

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