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Laser Metal Deposition of NiTi Shape Memory Alloys: Influence of Process Parameters on Thermal Profiles and Part Properties
No full textLaser Metal Deposition (LMD), a laser powder–directed energy deposition technology (LP-DED), offers unique flexibility for fabricating complex metallic components. Among candidate materials, Nitinol (NiTi) is particularly attractive due to its shape memory and superelastic properties, though its high sensitivity to processing conditions demands precise parameter control. In this work, prealloyed NiTi powder was deposited as single tracks, and process parameters were optimized using a Design of Experiments methodology. A Central Composite Design (CCD) was implemented with laser power, scan speed, and powder feed rate as inputs, while track’s height, width, aspect ratio, and dilution served as optimization responses. To address the strong susceptibility of NiTi to heat accumulation, hatch spacing was further optimized using a geometrically derived formula, enabling the use of maximum spacing while ensuring dense parts with smooth surfaces and minimal waviness. The presented framework establishes a systematic route for parameter optimization in NiTi LMD, offering practical guidelines for balancing densification and surface quality
Influence of laser power on the melt pool shape of handheld laser beam welding of 1.5 mm thick micro alloyed steel
No full textManual welding of structures requires highly skilled welders due to the large heat-affected zone of arc-based processes, that can negatively impact microstructure and cause distortion. Handheld laser beam welding is a promising alternative with high welding velocity and a concentrated heat input. However, its current use in industry is limited to parts with aesthetic requirements, often made of high-alloyed steel. To extend the use of handheld laser beam welding to low-cost steels with good mechanical properties, this study investigates the influence of laser power on the melt pool shape for micro-alloyed steel with a thickness of 1.5 mm. Tested joint geometries are T-joints welded with filler wire as well as butt joints and overlap joints without filler wire, which are typically found in assemblies under mechanical load. Weld quality is assessed by weld porosity analysis. The results show that the handheld laser beam welding with filler wire produces T-joints with a very good external appearance, but with porosity between level C and D in the cross sections according to DIN EN ISO 13919-1. By increasing the laser power, a deep penetration of the T-joint zone can be achieved without increasing the actual throat thickness. For handheld laser beam welding of butt joints a full penetration weld of the highest quality class can be reached. Overlap joints can be welded with full or partial penetration depending on the laser power selected, with quality classes between B and C in terms of porosity
ReguΛarity - A free software for the objective quantification of the regularity of periodic surface structures generated by femtosecond laser irradiation
No full textThe precise laser-based surface structuring on the micro- and nanoscale allows to create functional properties for innovative applications, e.g., in medicine, optics and biology. Among the various types of surface structures, laser-induced periodic surface structures (LIPSS) are characterized by their versatility and the relatively simple manufacturing process. However, the fabrication of highly regular LIPSS patterns remains challenging. The systematic investigation of LIPSS formation, as well as of the resulting functional properties requires a precise evaluation of the surface morphology, especially with regard to periodicity and regularity. Existing quantification methods such as Fast Fourier Transformation (FFT) tend to lack automation and objectivity, especially when dealing with large data sets and multi-scale structures. Although automated approaches exist with the Gini coefficient and the P³S method, their limited availability restricts a broader scientific use. We therefore introduce ReguΛarity as an innovative open-source software solution for objective, rapid and reproducible evaluation of structured surfaces concerning their regularity. In order to provide comprehensive surface morphological analysis, our software uses advanced image-processing techniques and integrates the already developed tools such as P³S method, Gini coefficient, FFT analysis, and the calculation of DLOA (Dispersion of LIPSS Orientation Angle). The software allows to evaluate any relevant image format as provided, e.g., by standard scanning electron micrographs. An intuitive PyQt5-based interface, enhanced by multi-threading capabilities, facilitates efficient data processing. Interactive features such as region-of-interest selection and plotting provide flexible adaptation to diverse applications. ReguΛarity offers a robust analysis tool that will contribute to the further development of precise laser-based surface structuring and to the optimization of the desired functional properties in both research and industry
Measurement of Lateral Size of Graphene Oxide Flakes by SEM - An Update of the VAMAS TWA 41 Project P13
No full textThe progress of the VAMAS interlaboratory comparison Project P13 "Lateral size of graphene oxide flakes by SEM" within the Technical Working Area 41 "Graphene and Related 2D Materials" is presented. The challenges at sample preparation on substrates for accurate measurement and image analysis as well as two different image analysis approaches, containing exact guidance how to measure the main descriptors for the lateral size measurement of the imaged graphene oxide flakes with Scanning Electron Microscopy are described. Discrepancies are explained. The inclusion of the results into the corresponding ISO technical specification CD/TS 23879 is also discussed and planned, in relation with the AFM part
Simulating Microbiologically Influenced Corrosion (MIC) at Seabed Environment in Monopile
No full textEnsuring the safety of offshore wind structures (OWS) is critical to guaranteeing their long-term performance and supporting reliable green energy supply. Microbiologically influenced corrosion (MIC) presents a significant challenge, particularly for monopiles in seabed environments. This study investigates the behavior of microorganisms and their impact on the corrosion process of carbon steel within monopiles. To simulate MIC at the sediment/water interface, an in-house experimental column was developed and inoculated with sediment and water samples from the North Sea. The system was operated under varying flow rates to replicate seabed movement conditions. Multiple molecular microbiological methods, surface analysis techniques, and other approaches were employed to assess the effects of different treatments. This study provides insights into MIC mechanisms in offshore environments and supports the development of strategies to monitor MIC in OWS infrastructur
Site-selectivity of Phl p 5 Modifications and their Influence on the Inflammatory Potential
No full textObjective: Resolve how peroxynitrite and O3/NO2 reshape tyrosine chemistry in Phl p 5 and modulate TLR4 activation. Design: Recombinant Phl p 5 underwent defined ONOO−:Y titrations and O3/NO2 exposures. ND, HOY-D, and dityrosine cross-links were quantified; modified residues were assigned; TLR4 responses were benchmarked to native.
Key results: Y285 exhibited highest susceptibility across pathways; Y236 remained unmodified. ND peaked at ONOO−:Y = 3:1 and at O3/NO2 = 10/200 ppb. The strongest hydroxylation arose with 200 ppb O3, predominating at Y112 and Y285. Cross-linking patterns diverged: ONOO− increased domain-1 connectivity while suppressing head/tail links; NO2 shifted cross-linking toward head/tail positions.
Biological effect: ONOO− did not raise TLR4 activity, whereas 200 ppb O3 produced a ~6% increase. Conclusion: Phl p 5 modification is residue- and chemistry-specific. Ozone-driven hydroxylation correlates with higher TLR4 signaling, while peroxynitrite-driven nitration/cross-linking leaves TLR4 unchanged. These relationships pinpoint reactive hotspots and suggest exposure-dependent mechanisms in pollutant-enhanced allergenicity
Stress-Optimised Welding Repair for High-Strength Offshore Steel Joints
No full textThe successful energy transition in Germany will require offshore wind turbines with outputs >10 MW in the future. To achieve these high outputs, turbines far from the coast are required, featuring large subsea jacket structures (30 m up to 50 m) and tall towers (up to 200 m). High-strength steels with a yield strengths up to 500 MPa and wall thicknesses of up to 120 mm are increasingly being used for these structures. During manufacture, weld defects detected by non-destructive testing (NDT) require localized repair (gouging and rewelding). To date, there is a lack of repair concepts and information in standards and guidelines. Therefore, BAM initiated the FOSTA project P1629 (IGF 01IF22746N) to investigate the stress-optimized repair (local gouging and welding) of high-strength thick plate joints made of offshore grades in the yield strength range off 355 to 460 MPa and similar weld metal. This research aims to develop a stress-optimized repair concept for thick plate joints, using controlled high-performance GMAW processes and optimized, narrow gouging grooves. Thermal and mechanical gouging are performed, allowing the groove configuration to be modified. Modern welding processes provide deep root penetration and focused energy input capable of welding narrow seams. The aimed residual stress reduction can be attributed to the lower input of weld metal due to the changes in groove configuration and to the reduction in heat input per layer due to the controlled arc process. The experimental analyses take into account the interaction of process, material, and design-related influences on the formation of weld induced stresses. Concluding with recommendations for guidelines elaborated for steel-processing SMEs
Development of a platform for benchmarking of simulation models for verification and validation
No full textThis presentation introduces a modular and open platform developed by BAM for the verification and validation (V&V) of simulation models, particularly material models used across various solvers. The platform aims to enhance transparency, reproducibility, and comparability in computational engineering by integrating standardized workflows, benchmark datasets, and semantic technologies.
Key components include:
Simulation workflows powered by tools like Snakemake and JupyterHub,
Research Object Crates (ROCrates) for structured data and provenance tracking,
Ontologies and knowledge graphs to semantically describe models, data, and results,
Federated registries for storing and querying benchmark results and ROCrates.
The platform supports both verification (e.g., analytical comparisons, convergence studies) and validation (e.g., experimental data matching), and facilitates tool-independent performance metrics using standardized output formats. It promotes collaborative development through containerized environments, automated testing, and reproducible research practices.
This initiative contributes to the broader goal of ensuring safety in technology and chemistry, aligning with BAM’s mission and supporting the scientific community in developing reliable simulation models
Trace-Level Ammonia–Water Interactions in Hydrogen: Challenges in Gas Purity Analysis Using Optical-Feedback Cavity-Enhanced Absorption Spectroscopy (OF-CEAS)
No full textAmmonia is a critical impurity in hydrogen fuel due to its irreversible poisoning effect on proton exchange membrane fuel cells. Therefore, international standards (e.g., ISO 14687) set a stringent threshold of 100 nmol/mol. Furthermore, with the growing potential use of ammonia as a hydrogen carrier, its accurate quantification is becoming increasingly important. However, the presence of trace humidity poses analytical challenges, as ammonia may interact with water or interfaces, thereby affecting its detectability. Therefore, the goal of this work is to enable accurate trace ammonia quantification for hydrogen purity measurements through fundamental studies of the methodological challenges. Here, low-pressure sampling (ultra)long-path Optical-Feedback Cavity-Enhanced Absorption Spectroscopy (OF-CEAS) was applied with an effective optical path length of approximately 6.17 km. We studied three average amounts of ammonia: (38.2 ± 0.8) nmol/mol, (74.8 ± 0.7) nmol/mol, and (112.1 ± 1.2) nmol/mol. Furthermore, these amounts were investigated at trace-humidity levels ranging from 0.8 to 8.5 ppmV. We observed a systematic, nonlinear, and humidity-dependent positive measurement bias of up to + (1.0 ± 0.2) nmol/mol at the maximum investigated trace-humidity volume fraction of 8.5 ppmV. This bias was not caused by spectral interference but rather by water-induced accumulation of ammonia within the optical cavity. Moreover, time-resolved measurements in the presence of trace ammonia showed that water desorption follows first-order kinetics, whereas water adsorption followed mixed-order kinetics with an apparent reaction order of 1.57 ± 0.03. Distinct hydration states of surface-bound ammonia were identified, whereas under dry conditions and with increasing amounts of ammonia, enhanced surface adhesion through intermolecular clustering was observed. In addition, the presence of ammonium species within the sorption layer was indirectly confirmed by our experiments. In conclusion, we provide a deeper insight into trace-level ammonia–water interactions and establish a framework for optimizing methodologies, particularly for (ultra)long-path optical gas measurement systems
Standardized Measurements of Surface Functionalities on Nanoparticles - F. Synthesis and characterization of functional nanocomposite materials
No full textEngineered nanoparticles (NPs) with various chemical compositions and surface functionalities are routinely and commonly fabricated for industrial applications such as medical diagnostics, drug delivery, sensing, catalysis, energy conversion and storage, opto-electronics, and information storage. NP function, their interaction with biological species, and also their environmental fate are largely determined by the surface functionalities of the particles. Reliable, reproducible, and standardized surface characterization methods are therefore vital for quality control of NPs, determination of their applicability, and mandatory to meet increasing concerns regarding their safety. In addition, industry as well as international standardization organizations, regulatory agencies, and policymakers need validated and standardized measurement methods and reference materials.
However, methodologies for determining NP surface properties, including the amount, chemical composition, and homogeneity of surface functionalities and coatings are largely non-standardized up until now. Suitable methods for determining surface functionalities on ligand-stabilized core and core/shell NPs include advanced techniques such as traceable quantitative nuclear magnetic resonance (qNMR), as well as X-ray electron spectroscopy (XPS) and time of flight secondary ion mass spectrometry (ToF-SIMS), and simpler optical and electrochemical methods. The latter, typically less costly methods are often used by SMEs, e.g., for quality control. To validate methods, establish measurement uncertainties, test reference materials, and produce reference data, international interlaboratory comparisons (ILC) on NP surface functionalization measurements are required to provide well characterized test and reference nanomaterials including benchmark values.[1] These needs are addressed by the current European metrology project SMURFnano, involving 12 partners from different National Metrology Institutes, designated and research institutes, two university groups as well as one large company and one SME producing NPs. This project, as well as first results derived from the development of test and reference materials with a well characterized surface chemistry, and ongoing interlaboratory comparisons, will be presented