Additive Manufacturing of Functional Elements on Sheet Metal

Journal article

Publication Details

Author(s): Schaub A, Ahuja B, Butzhammer L, Osterziel J, Schmidt M, Merklein M
Journal: Physics Procedia
Publisher: Elsevier BV
Publication year: 2016
Volume: 83
Pages range: 797-807
ISSN: 1875-3892
eISSN: 1875-3884
Language: English


Laser Beam Melting (LBM) process with its advantages of high design flexibility and free form manufacturing methodology is often applied limitedly due to its low productivity and unsuitability for mass production compared to conventional manufacturing processes. In order to overcome these limitations, a hybrid manufacturing methodology is developed combining the additive manufacturing process of laser beam melting with sheet forming processes. With an interest towards aerospace and medical industry, the material in focus is Ti-6Al-4V. Although Ti-6Al-4V is a commercially established material and its application for LBM process has been extensively investigated, the combination of LBM of Ti-6Al-4V with sheet metal still needs to be researched. Process dynamics such as high temperature gradients and thermally induced stresses lead to complex stress states at the interaction zone between the sheet and LBM structure. Within the presented paper mechanical characterization of hybrid parts will be performed by shear testing. The association of shear strength with process parameters is further investigated by analyzing the internal structure of the hybrid geometry at varying energy inputs during the LBM process. In order to compare the hybrid manufacturing methodology with conventional fabrication, the conventional methodologies subtractive machining and state of the art Laser Beam Melting is evaluated within this work. These processes will be analyzed for their mechanical characteristics and productivity by determining the build time and raw material consumption for each case. The paper is concluded by presenting the characteristics of the hybrid manufacturing methodology compared to alternative manufacturing technologies.

FAU Authors / FAU Editors

Ahuja, Bhrigu
Lehrstuhl für Photonische Technologien
Butzhammer, Lorenz
Lehrstuhl für Photonische Technologien
Merklein, Marion Prof. Dr.-Ing.
Institute of Manufacturing Technology
Schaub, Adam
Institute of Manufacturing Technology
Schmidt, Michael Prof. Dr.-Ing.
Lehrstuhl für Photonische Technologien

Additional Organisation
Sonderforschungsbereich 814/3 Additive Fertigung

How to cite

Schaub, A., Ahuja, B., Butzhammer, L., Osterziel, J., Schmidt, M., & Merklein, M. (2016). Additive Manufacturing of Functional Elements on Sheet Metal. Physics Procedia, 83, 797-807.

Schaub, Adam, et al. "Additive Manufacturing of Functional Elements on Sheet Metal." Physics Procedia 83 (2016): 797-807.


Last updated on 2018-18-10 at 02:00