Ass.-Prof. Dr. Lukas Kaserer
Materials science with focus on mechatronics
Our research group focuses on materials and processes for powder-bed-based additive manufacturing—commonly known as 3D printing—of metallic materials. In this process, metal powder is selectively fused in a layer-by-layer build-up process using a laser or electron beam. This enables the resource-efficient production of components that are individually tailored and fabricated in complex, highly-functional geometries. Additionally, the specific process conditions of additive manufacturing allow the development of novel materials with unique microstructures and optimized mechanical properties.
The core of our work involves alloy development, meaning the development of new, customized materials using thermodynamic calculations, and simulation-based process development to establish process strategies for the defect-free processing of innovative materials. We place a particular emphasis on high-melting materials like molybdenum and tungsten, titanium and aluminum alloys, and steels. For our application-oriented research projects, we collaborate closely with partners from academia and industry.
Laser powder bed fusion at the end of the production process. In this process, metal powder is fused using a high-performance laser in a layer-by-layer build-up process.
In powder-bed-based additive manufacturing, metallic materials solidify under extreme temperature gradients and high cooling rates. In addition, during the layer-by-layer process, previously solidified material is reheated, resulting in complex temperature distributions within the component. Materials originally developed for conventional manufacturing processes often face limitations here and can be challenging to process additively. Therefore, further development and innovation in alloy design for powder-bed-based additive manufacturing are essential to improve processability and optimize material properties.
Laboratory of the materials science working group.
The aim of process development for powder-bed-based additive manufacturing is to precisely understand and control the material-specific interaction between process parameters, process conditions, and material properties—both for newly developed and established materials. For this purpose, we employ simulation-based methods and use sensor data from process monitoring tools, such as inline pyrometers and high-speed cameras. This data is complemented by comprehensive analyses of the microstructure and mechanical properties of the components to achieve targeted optimization and adaptation of the process workflows.
VOF simulation of the Laser Powder Bed Fusion process.
Modeling and VOF/FEM simulation of additive manufacturing aim to gain a comprehensive understanding of the interactions among the numerous manufacturing parameters and the process and material properties in this dynamic and highly complex physical process. For example, we investigate factors affecting melt pool dynamics, as well as the role of process atmosphere and powder quality, to minimize defects such as pore formation. Additionally, we examine solidification conditions and the material’s thermal history to precisely control and optimize the microstructural and mechanical properties of our materials.