Advanced Materials Research Vol. 22

Abstract: This paper deals with the measurement and the detection of errors in the threedimensional geometry of high-strength structure components. Firstly different geometrical measuring systems and their usability for the measurement of high-strength structure components are discussed. An optimized solution is suggested, an adaptive projection method based on pattern projection is introduced. The technique takes care of the special properties of high-strength structure components within the production process. The measurement procedure is divided into two steps. Within the adaptation-step the luminescence and the resolution of the projected pattern is adapted on the measured object. The actual picture is taken and calculated in a second step in order to avoid vibrations. The paper concludes with a description of the data processing procedures necessary in order to evaluate the correctness of the measured structure and describes how a 100% geometrical quality control can be achieved using the described methods.

Abstract: A fast transfer of new manufacturing- and material technologies to actual design use is only to be expected if calculation concepts exist, which allow an easy estimation of the parts’ strength properties. This Collaborative Research Project (CRP) will develop new manufacturing and joining techniques to create high strength structures by adjusting the local strength properties of parts. These types of structures are usually loaded dynamically. To specifically optimise the fatigue behaviour, stiffness and weight of a structure, the influences of locally strengthening manufacturing processes must be considered in the fatigue life calculation concept. It is the goal of this project to include a simulation of the fatigue behaviour in the process simulation of manufacturing. Recently research on the influence of local strengthening by cold forming on fatigue life was undertaken in cooperation within another research project. The fatigue life calculation of sheet metal structures can be based on a calculation concept developed in CRP 362, subproject C5, which takes into account the influence of forming, [1,2,3,4]. This concept shall be extended to incorporate the effects of local martensite forming in the cold formed areas.

Abstract: The advantages of low heat joining techniques, such as low distortion and little influence on the local material properties due to the low introduced amount of heat, shall be made usable for the manufacture of high strength structures by increasing the process reliability. The dependency between the parameters of the joining process, the seam geometry, the type of solder, the load type und the fatigue life especially of soldered structure with local strengthening shall be examined to allow a calculative estimation of the part’s life.

Abstract: Modern metallic materials used in high loading structures are increasingly being placed under stringent standards with regard to the mechanical strength and deformation properties of their individual parts as well as with regard to the loading capacity of their junctions. In order to determine the strain profile of the individual structural components, the mentioned topics will be taken from the SFB 675 “High tensile, locally manipulated structural components and structures” from the subproject C4 “Setting of gradient material properties and qualification of high-tension 3D-NVEB weld joints”. To this end, the strengthened individual structural components will be heated with an electron beam at defined locations. This is done in order to observe the load related local micro-structure changes and consequently the targeted, structured local changes in the strength and deformation properties of the material. A delay in the crack growth will also be sought after. Additionally, components with specifically designed tensile strength will be welded to high quality structures. At this the young but efficient non vacuum electron beam welding method will be preferably developed, qualified and used because of its good welding properties regarding to an improved beam positioning, process control and weld joint defect detection.

Abstract: New interdisciplinary material and manufacturing technologies make local configuration of material properties possible. The availability of material property information in the early construction process and adequate welding technologies are essential needs to realize a maximum utilization of material. The research objective of two cooperating institutes at the Technical University of Clausthal is to develop a design strategy with related design rules in order to engineer high strength coupling elements of requirement optimized composite materials. Special attention is paid to the usage of future welding technologies and their influence on material properties of locally altered materials. Further objective is an early survey of the consequences caused by the usage of locally altered materials in mixed architecture design projects to the whole production process.