Es wird ein Einblick in die Vorgehensweise zur Fertigung von Knotenstrukturen im Stahlbau mittels Wire and Arc Additive Manufacturing (WAAM) und der numerischen und experimentellen Untersuchung der Knotenstrukturen gegeben. Ausgehend von der geometrischen Komplexität sich schneidender Profilstäbe aus Stahl werden wesentliche Punkte bei der simulationsgestützten Ermittlung von Knotenstrukturen beschrieben. In Abhängigkeit von den Lastfällen können unterschiedliche Strukturen in der Topologieoptimierung gefunden werden. Für die Herstellung der Knotenstruktur durch das Wire and Arc Additive Manufacturing müssen die numerisch gefundene Geometrie angepasst sowie Varianten der Bahnplanung entwickelt und bewertet werden. Dabei wird auch der Einfluss von Prozessparametern auf Verzug, Endkonturnähe und mechanische Eigenschaften der Bauteile untersucht. Für die Prognose von Spannungs‐ und Verformungszuständen des Knotens wird eine vereinfachte thermische und mechanische Analyse des Herstellungsprozesses durchgeführt. Weiter wird ein Verfahren für eine In‐situ‐Bauteilprüfung vorgestellt, welche Prozessunregelmäßigkeiten anhand von Sensordaten erkennt und deren Einflüsse auf die mechanischen Eigenschaften des Bauteils bewertet, wodurch frühzeitig im Prozess Maßnahmen zur Fehlerkorrektur getroffen oder Kosten durch Ausschuss reduziert werden können.

An insight into the procedure for manufacturing node structures in steel construction using Wire and Arc Additive Manufacturing (WAAM) and the numerical and experimental investigation of the node structures is given. Based on the geometric complexity of intersecting steel profile bars, essential points in the simulation-based determination of node structures are described. Depending on the load cases, different structures can be found via topology optimization. For the production of the node structure by wire and arc additive manufacturing, the numerically found geometry must be adapted and path planning variants have to be developed and evaluated. The influence of process parameters on warpage, near net shape and mechanical properties of the components is also examined. A simplified thermal and mechanical analysis of the manufacturing process is carried out for the prognosis of the stress and deformation states of the node. Furthermore, a method for in-process quality assurance is presented, which recognizes process irregularities on the basis of sensor data and evaluates their influence on the mechanical properties of the component, whereby measures for error correction can be taken early in the process and costs through rejects can be reduced.

Purpose This study aims to characterize the suitability of a direct extrusion process in the fused layer manufacturing (FLM)-method under processing of granulated plastics. Design/methodology/approach In this paper, a granulate-based direct extrusion system in the FLM method is presented. This system is characterized with respect to the strand deposition mechanism and resulting component properties (geometrically and mechanically). Findings The extruder output could be identified as a linear relation between the applied extruder speed and the resulting mass flow. A developed model for the material and temperature-dependent strand deposition process was validated under experimental investigations. Further, it was possible to define process windows to realize desired strand widths and strand heights. In addition, analyses were conducted to determine the tensile strength transversely to the orientation of the layer plane. Research limitations/implications The extrusion system was characterized under the processing of materials ABS Magnum 8434 and PLA Ingeo 4043D. Due to the restricted choice of materials, further investigations are planned under an extension of the test materials. Furthermore, the degree of the geometric complexity of the test components should be increased to finally characterize the process. Originality/value By means of the characterization of the direct extrusion system, it is possible for users to classify the process and to use the process in specific application areas. In comparison to filament-based extrusion systems, significant advantages can be achieved by means of direct extrusion. These include, for example, the use of less expensive work materials (by factor >10), the use of existing test certificates and the advantage of higher mechanical properties. This makes it possible to meet modern product requirements and to produce competitive components.