sponsored by the state of Berlin
Project start: January 2023
Duration: 2,5 years
Funded with: approx. 8 Mio. €
Number of partners: 11
Location Huttenstraße
Christoph Heinze, Siemens Energy
Project Management
Cynthia Wirth, Siemens Energy
Project Management
Insights into our work
Here we document important milestones from the project. Current news, special publications or appearances at trade fairs and congresses are made visible here.
SEP
2024
NEWS
proof-of-concept for improving holistic material utilization in AM
Within our work package NP-4, by-products of the Laser Powder-Bed Fusion process from Siemens Energy’s manufacturing, which were previously classified as scrap, were sent to a powder manufacturer as recycling material. This included so-called “end-of-life” powder, support structures, and non-conformance components. After a complete chemical analysis, it was proven that specification-compliant recycling material can be atomized into compliant powder again without re-alloying. This is a crucial proof for improving holistic material utilization in additive manufacturing. Following the technical proof, discussions on the economic implementation are now taking place between the companies.
SEP
2024
NEWS
proof-of-concept for improving holistic material utilization in AM
Within our work package NP-4, by-products of the Laser Powder-Bed Fusion process from Siemens Energy’s manufacturing, which were previously classified as scrap, were sent to a powder manufacturer as recycling material. This included so-called “end-of-life” powder, support structures, and non-conformance components. After a complete chemical analysis, it was proven that specification-compliant recycling material can be atomized into compliant powder again without re-alloying. This is a crucial proof for improving holistic material utilization in additive manufacturing. Following the technical proof, discussions on the economic implementation are now taking place between the companies.
JUN
2024
NEWS
2nd milestone meeting
The second milestone meeting of the project took place on 20.06.24 at the TU Berlin. Results from material and process development, post-processing and sustainable product creation were presented in reports and a poster session on all 12 work packages. Progress was made, for example, in the evaluation of the process parameter field for titanium aluminides, the robot-assisted processing of PBF-LB/M H282 and the recycling of PBF-LB powders. The next meeting is planned for 23.01.2025 at the IPK, focusing on “post-processing” with a live demo.
JUN
2024
NEWS
2nd milestone meeting
The second milestone meeting of the project took place on 20.06.24 at the TU Berlin. Results from material and process development, post-processing and sustainable product creation were presented in reports and a poster session on all 12 work packages. Progress was made, for example, in the evaluation of the process parameter field for titanium aluminides, the robot-assisted processing of PBF-LB/M H282 and the recycling of PBF-LB powders. The next meeting is planned for 23.01.2025 at the IPK, focusing on “post-processing” with a live demo.
JAN
2024
NEWS
1st milestone meeting
First milestone meeting “check”. We met at BAM on 25.01.24 for our first project review with IBB and the experts from VDI/VDE. It was a successful day, which shows that we are working in a productive team on interesting tasks such as process development, post-processing, simulation, life cycle analysis, recycling, etc.
JAN
2024
NEWS
1st milestone meeting
First milestone meeting “check”. We met at BAM on 25.01.24 for our first project review with IBB and the experts from VDI/VDE. It was a successful day, which shows that we are working in a productive team on interesting tasks such as process development, post-processing, simulation, life cycle analysis, recycling, etc.
2023
NEWS
HTA2 Deep Dives
Within the first months of the project, deep dives were carried out in our workstreams “Materials & Processes”, “Post-Processing” and “Sustainable Product Development” for the entire consortium. The aim was to describe the main fields of work and objectives of the 12 work packages and to encourage an exchange between the workstreams. Around 25 participants at each of the three sessions took advantage of this opportunity for networking and coordination, paving the way for the first milestone meeting in January 2024.
2023
NEWS
HTA2 Deep Dives
Within the first months of the project, deep dives were carried out in our workstreams “Materials & Processes”, “Post-Processing” and “Sustainable Product Development” for the entire consortium. The aim was to describe the main fields of work and objectives of the 12 work packages and to encourage an exchange between the workstreams. Around 25 participants at each of the three sessions took advantage of this opportunity for networking and coordination, paving the way for the first milestone meeting in January 2024.
JUL
2023
NEWS
Kick-Off
On July 11, 2023, the partners, IBB and the review team met to get to know each other and get an overview of the Phase II roadmap. Research topics include design for additive manufacturing, life cycle analysis, process and material development, robotic post-processing, FEM simulations, high-energy synchrotron experiments, powder/support structure recycling, and more.
JUL
2023
NEWS
Kick-Off
On July 11, 2023, the partners, IBB and the review team met to get to know each other and get an overview of the Phase II roadmap. Research topics include design for additive manufacturing, life cycle analysis, process and material development, robotic post-processing, FEM simulations, high-energy synchrotron experiments, powder/support structure recycling, and more.
With us:
In the project, BAM is developing new methods for in-situ quality assurance and an understanding of microstructure development and creep behavior. In this way, we are contributing to the safe and reliable use of AM components.
Kai Hilgenberg
Project manager HTA at BAM
Additively manufactured components are often not immediately ready for use after printing. Fraunhofer IPK is therefore conducting intensive research into automated post-processing in order to enable production with the highest possible efficiency in batch size 1, even for the most complex geometries.
Tobias Neuwald
Project manager HTA at Fraunhofer IPK
For Siemens Energy, HTA 2.0 is a comprehensive research project in the field of additive manufacturing with a wide range of partners in Berlin. It is characterized by excellent cooperation and exciting research aspects, where we shed light on relevant topics such as process development, digitalization, efficiency increase along the process chain and sustainability. We want to take additive manufacturing into further products and are grateful for the support of our partners in implementing this.
Christoph Heinze
Project manager
The project in pictures
Science, research and education
Following the successful completion of HTA2.0 at the end of 2022, the 2nd phase will start in January 2023 with a duration until June 2025. Here, we welcome new partners within the HTA network and look forward to working together.
What it’s all about
High-temperature applications involve the development and production of components that come into contact with the hot gas jet, which reaches temperatures of well over 1000 degrees Celsius, in high-efficiency gas-fired power plants. To ensure their function and service life, additive manufacturing is used to implement innovative concepts that are not technically feasible using conventional manufacturing processes.
Aims of the research project
Development of new additive manufacturing processes and components for high-temperature components in large gas turbines, taking into account sustainable product development.
Motivation
The focus of the 2nd phase is the extension of the Design for Additive Manufacturing method with further processes (wire-based generation of large components DED-Arc, selective laser beam melting with high-temperature preheating and selective electron beam melting PBF-EB/M in powder bed) and the aspect of life cycle analysis (LCA). In this context, process and material development for the DED-Arc and PBF-EB/M processes will be brought to a higher level of maturity.
Furthermore, the topic of post-processing of additively manufactured components is being given greater attention in order to enable automated and small-series processing. In addition, the recycling of metal powders and support structures will be highlighted, with the aim of achieving greater resource efficiency and thus contributing to the economic presentation of AM components.
The consortium
The “Werner-von-Siemens Centre for Industry and Science” ecosystem is a colorful mix of renowned scientific institutions and universities, excellent industry, innovative SMEs and agile, young companies. They all combine their expertise in a future-oriented research cooperation.
The project partners are:
The Werner-von-Siemens Centre for Industry and Science e.V. is supported by federal and state funds within the framework of the Joint Task “Improvement of the Regional Economic Structure” (GRW).
Our projects are co-financed by the European Regional Development Fund (ERDF).
