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Department of Mechanical Engineering

Forming of Additively Manufactured Sandwich Sheets with Optimized Core Structures

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  • Materialcharakterisierung
  • Technologieentwicklung
  • ReGAT
a) Large semi-finished sheet, b) Material-fit and form-fit joint, c) Shear strength of the connections and shear test © IUL
a) Large semi-finished sheet, b) Material-fit and form-fit joint, c) Shear strength of the connections and shear test
Funding German Research Foundation (DFG)
Project 317137194
Contact Stephan Rosenthal M. Sc.

In cooperation with the Institute of Product Engineering at the University of Duisburg-Essen, sandwich sheet composites with core structures optimized for forming are being developed. The additively manufactured core is joined with rolled cover sheets and enables the production of load-adapted semi-finished products to overcome the build-space restrictions of additive manufacturing machines. For composite manufacturing form-fit and material-fit processes are characterized in terms of their suitability for a subsequent forming operation by means of shear tests. The material bond is achieved by local welding of weld spots and cover sheets with short high-current pulses. In particular, the identification of the process parameters plays a central role. A form-fit connection is produced by a trunnion joint with trunnion geometries optimized for forming. Shear tests show a higher strength in favor of the form-fit connection (see figure). Improvements in the welding process are expected to enhance the performance of the material-joint connection.