Selectiv electron beam melting of special alloys

   We examine the possibility to process high performance alloys such as non-weldable Nickel-base alloys or special Copper alloys by means of SEBM. There are also experiences in the processing of Titanium alloys, in particular for medical applications, Titanium aluminides and steels.
   We also study the fundamentals of material science and reaction technology for the simultaneous production of carrier material and catalytic function of structured reactors made by SEBM. The active catalyst (Raney copper type) develops from the AM manufactured structure by leaching. Thus, geometric restrictions of complex coating processes for catalytic functionalization disappear. The direct generation of the catalytically active material on the carrier structure is expected to show advantages with respect to thermal management.

• Yang J., Fu Z., Körner C.:
  Structure Design of Soft Magnetic Materials using Electron Beam‐based Additive Manufacturing
  In: Advanced Materials (2023)
  ISSN: 0935-9648
  DOI: 10.1002/adma.202300837
• Fu Z., Ye J., Franke M., Körner C.:
  A novel approach for powder bed-based additive manufacturing of compositionally graded composites
  In: Additive Manufacturing 56 (2022), Article No.: 102916
  ISSN: 2214-7810
  DOI: 10.1016/j.addma.2022.102916
• Yang J., Fu Z., Ye J., Kübrich D., Körner C.:
  Electron beam-based additive manufacturing of Fe93.5Si6.5 (wt.%) soft magnetic material with controllable magnetic performance
  In: Scripta Materialia 210 (2022), Article No.: 114460
  ISSN: 1359-6462
  DOI: 10.1016/j.scriptamat.2021.114460
• Knoerlein J., Franke MM., Schloffer M., Körner C.:
  In-situ aluminum control for titanium aluminide via electron beam powder bed fusion to realize a dual microstructure
  In: Additive Manufacturing 59 (2022)
  ISSN: 2214-7810
  DOI: 10.1016/j.addma.2022.103132
• Hofer A., Wachter S., Döhler D., Laube A., Sánchez Batalla B., Fu Z., Weidlich C., Struckmann T., Körner C., Bachmann J.:
  Practically applicable water oxidation electrodes from 3D-printed Ti6Al4V scaffolds with surface nanostructuration and iridium catalyst coating
  In: Electrochimica Acta 417 (2022), p. 140308
  ISSN: 0013-4686
  DOI: 10.1016/j.electacta.2022.140308
• Reith M., Breuning C., Franke M., Körner C.:
  Impact of the Power-Dependent Beam Diameter during Electron Beam Additive Manufacturing: A Case Study with γ-TiAl
  In: Applied Sciences 12 (2022), Article No.: 11300
  ISSN: 2076-3417
  DOI: 10.3390/app122111300
• Poller MJ., Renz C., Wolf T., Körner C., Wasserscheid P., Albert J.:
  3D-Printed Raney-Cu POCS as Promising New Catalysts for Methanol Synthesis
  In: Catalysts 12 (2022)
  ISSN: 2073-4344
  DOI: 10.3390/catal12101288
• Kotzem D., Teschke M., Jüchter V., Körner C., Walther F.:
  Microstructure analysis and mechanical properties of electron beam powder bed fusion (PBF-EB)-manufactured gamma-titanium aluminide (TiAl) at elevated temperatures
  In: MP Materials Testing 64 (2022), p. 636-646
  ISSN: 0025-5300
  DOI: 10.1515/mt-2021-2137
• Guschlbauer R.:
  Grundlagen des selektiven Elektronenstrahlschmelzens von Reinkupfer (Dissertation, 2022)
• Wahlmann B., Krohmer E., Breuning C., Schell N., Staron P., Uhlmann E., Körner C.:
  In‐situ Observation of γ' Phase Transformation Dynamics during Selective Laser Melting of CMSX‐4
  In: Advanced Engineering Materials (2021)
  ISSN: 1438-1656
  DOI: 10.1002/adem.202100112
• Reith M., Franke M., Schloffer M., Körner C.:
  Processing 4th generation titanium aluminides via electron beam based additive manufacturing – characterization of microstructure and mechanical properties
  In: Materialia 14 (2020), Article No.: 100902
  ISSN: 2589-1529
  DOI: 10.1016/j.mtla.2020.100902
• Bieske J., Franke M., Schloffer M., Körner C.:
  Microstructure and properties of TiAl processed via an electron beam powder bed fusion capsule technology
  In: Intermetallics 126 (2020), Article No.: 106929
  ISSN: 0966-9795
  DOI: 10.1016/j.intermet.2020.106929
• Wolf T., Fu Z., Ye J., Heßelmann C., Pistor J., Albert J., Wasserscheid P., Körner C.:
  Periodic open cellular Raney-Copper-Catalysts fabricated via selective electron beam melting
  In: Advanced Engineering Materials (2020)
  ISSN: 1438-1656
  DOI: 10.1002/adem.201901524
• Heßelmann C., Wolf T., Galgon F., Körner C., Albert J., Wasserscheid P.:
  Additively manufactured Raney-type Copper catalyst for methanol synthesis
  In: Catalysis: Science and Technology 10 (2020), p. 164-168
  ISSN: 2044-4753
  DOI: 10.1039/C9CY01657K
• Wolf T., Fu Z., Körner C.:
  Selective electron beam melting of an aluminum bronze: Microstructure and mechanical properties
  In: Materials Letters 238 (2019), p. 241-244
  ISSN: 0167-577X
  DOI: 10.1016/j.matlet.2018.12.015
• Meid C., Dennstedt A., Ramsperger M., Pistor J., Ruttert B., Lopez-Galilea I., Theisen W., Körner C., Bartsch M.:
  Effect of heat treatment on the high temperature fatigue life of single crystalline nickel base superalloy additively manufactured by means of selective electron beam melting
  In: Scripta Materialia 168 (2019), p. 124-128
  ISSN: 1359-6462
  DOI: 10.1016/j.scriptamat.2019.05.002
• Pobel C., Osmanlic F., Lodes M., Wachter S., Körner C.:
  Processing windows for Ti-6Al-4V fabricated by selective electron beam melting with improved beam focus and different scan line spacings
  In: Rapid Prototyping Journal 25 (2019), p. 665-671
  ISSN: 1355-2546
  DOI: 10.1108/RPJ-04-2018-0084
• Bürger D., Parsa AB., Ramsperger M., Körner C., Eggeler G.:
  Creep properties of single crystal Ni-base superalloys (SX): A comparison between conventionally cast and additive manufactured CMSX-4 materials
  In: Materials Science and Engineering A-Structural Materials Properties Microstructure and Processing 762 (2019), Article No.: 138098
  ISSN: 0921-5093
  DOI: 10.1016/j.msea.2019.138098
• Heßelmann C., Wolf T., Körner C., Albert J., Wasserscheid P.:
  Additive manufacturing meets reaction engineering - Novel Raney® copper catalyst structures for methanol synthesis
  2019 DGMK International Conference on Circular Economy - A Fresh View on Petrochemistry (Dresden, DEU, 9. October 2019 - 11. October 2019)
  In: H. Blanke, H. Hager, A. Jess, J. A. Lercher, M. Marchionna, D. Vogt, M. Bender (ed.): DGMK Tagungsbericht 2019
• Jüchter V., Franke M., Merenda T., Stich A., Körner C., Singer R.:
  Additive manufacturing of Ti-45Al-4Nb-C by selective electron beam melting for automotive applications
  In: Additive Manufacturing 22 (2018), p. 118-126
  ISSN: 2214-7810
  DOI: 10.1016/j.addma.2018.05.008
• Körner C., Ramsperger M., Meid C., Bürger D., Wollgramm P., Bartsch M., Eggeler G.:
  Microstructure and Mechanical Properties of CMSX-4 Single Crystals Prepared by Additive Manufacturing
  In: Metallurgical and Materials Transactions A-Physical Metallurgy and Materials Science 49 (2018), p. 3781-3792
  ISSN: 1073-5623
  DOI: 10.1007/s11661-018-4762-5
• Momeni S., Guschlbauer R., Osmanlic F., Körner C.:
  Selective electron beam melting of a copper-chrome powder mixture
  In: Materials Letters 223 (2018), p. 250-252
  ISSN: 0167-577X
  DOI: 10.1016/j.matlet.2018.03.194
• Guschlbauer R., Momeni S., Osmanlic F., Körner C.:
  Process development of 99.95% pure copper processed via selective electron beam melting and its mechanical and physical properties
  In: Materials Characterization (2018)
  ISSN: 1044-5803
  DOI: 10.1016/j.matchar.2018.04.009
• Pobel C., Lodes M., Körner C.:
  Selective Electron Beam Melting of Oxide Dispersion Strengthened Copper
  In: Advanced Engineering Materials 20 (2018)
  ISSN: 1438-1656
  DOI: 10.1002/adem.201800068
• Ramsperger M.:
  Selektives Elektronenstrahlschmelzen der einkristallinen Ni-Basis Superlegierung CMSX-4 (Dissertation, 2018)
• Jüchter V.:
  Grundlagen des Selektiven Elektronenstrahlschmelzens von Titanaluminiden (Dissertation, 2018)
• Scharowsky T., Bauereiß A., Körner C.:
  Influence of the hatching strategy on consolidation during selective electron beam melting of Ti-6Al-4V
  In: International Journal of Advanced Manufacturing Technology (2017), p. 1-10
  ISSN: 0268-3768
  DOI: 10.1007/s00170-017-0375-1
• Riedlbauer DR., Scharowsky T., Singer R., Steinmann P., Körner C., Mergheim J.:
  Macroscopic simulation and experimental measurement of melt pool characteristics in selective electron beam melting of Ti-6Al-4V
  In: International Journal of Advanced Manufacturing Technology (2017)
  ISSN: 0268-3768
  DOI: 10.1007/s00170-016-8819-6
  URL: http://link.springer.com/article/10.1007/s00170-016-8819-6
• Ruttert B., Ramsperger M., Mujica Roncery L., Lopez-Galilea I., Körner C., Theisen W.:
  Impact of hot isostatic pressing on microstructures of CMSX-4 Ni-base superalloy fabricated by selective electron beam melting
  In: Materials and Design 110 (2016), p. 720-727
  ISSN: 0261-3069
  DOI: 10.1016/j.matdes.2016.08.041
• Ramsperger M., Singer R., Körner C.:
  Microstructure of the Nickel-Base Superalloy CMSX-4 Fabricated by Selective Electron Beam Melting
  In: Metallurgical and Materials Transactions A-Physical Metallurgy and Materials Science 47 (2016), p. 1469-1480
  ISSN: 1073-5623
  DOI: 10.1007/s11661-015-3300-y
• Körner C., Ramsperger M.:
  Selective electron beam melting of the single crystalline nickel-base superalloy CMSX-4®: From columnar grains to a single crystal
  13th International Symposium on Superalloys, SUPERALLOYS 2016 (Seven Springs, 11. September 2016 - 15. September 2016)
  In: M. Hardy, E. Huron, U. Glatzel, B. Griffin, B. Lewis, C. Rae, V. Seetharaman, S. Tin (ed.): Superalloys 2016: Proceedings of the 13th Intenational Symposium of Superalloys 2016
  DOI: 10.1002/9781119075646.ch37
• Raab S., Guschlbauer R., Lodes M., Körner C.:
  Thermal and Electrical Conductivity of 99.9% Pure Copper Processed via Selective Electron Beam Melting
  In: Advanced Engineering Materials 18 (2016), p. 1661-1666
  ISSN: 1438-1656
  DOI: 10.1002/adem.201600078
• Parsa AB., Ramsperger M., Kostka A., Somsen C., Körner C., Eggeler G.:
  Transmission electron microscopy of a CMSX-4 Ni-base superalloy produced by selective electron beam melting
  In: Metals 6 (2016), Article No.: 258
  ISSN: 2075-4701
  DOI: 10.3390/met6110258
• Helmer H., Bauereiß A., Singer R., Körner C.:
  Erratum to: ‘Grain structure evolution in Inconel 718 during selective electron beam melting’ (Materials Science & Engineering A (2016) 668 (180–187 (S0921509316305536) (10.1016/j.msea.2016.05.046))
  In: Materials Science and Engineering A-Structural Materials Properties Microstructure and Processing 676 (2016)
  ISSN: 0921-5093
  DOI: 10.1016/j.msea.2016.09.016
• Helmer H., Bauereiß A., Singer R., Körner C.:
  Grain structure evolution in Inconel 718 during selective electron beam melting
  In: Materials Science and Engineering A-Structural Materials Properties Microstructure and Processing 668 (2016), p. 180-187
  ISSN: 0921-5093
  DOI: 10.1016/j.msea.2016.05.046
• Helmer H.:
  Additive Fertigung durch Selektives Elektronenstrahlschmelzen der Nickelbasis Superlegierung IN718: Prozessfenster, Mikrostruktur und mechanische Eigenschaften (Dissertation, 2016)
• Scharowsky T.:
  Grundlagenuntersuchungen zum selektiven Elektronenstrahlschmelzen von TiAl6V4 (Dissertation, 2016)
• Lodes M., Guschlbauer R., Körner C.:
  Process development for the manufacturing of 99.94% pure copper via selective electron beam melting
  In: Materials Letters 143 (2015), p. 298-301
  ISSN: 0167-577X
  DOI: 10.1016/j.matlet.2014.12.105
• Scharowsky T., Jüchter V., Singer R., Körner C.:
  Influence of the Scanning Strategy on the Microstructure and Mechanical Properties in Selective Electron Beam Melting of Ti-6Al-4V
  In: Advanced Engineering Materials 17 (2015), p. 1573-1578
  ISSN: 1438-1656
  DOI: 10.1002/adem.201400542
• Ramsperger M., Mujica Roncery L., Lopez-Galilea I., Singer R., Theisen W., Körner C.:
  Solution Heat Treatment of the Single Crystal Nickel-Base Superalloy CMSX-4 Fabricated by Selective Electron Beam Melting
  In: Advanced Engineering Materials 17 (2015), p. 1486-1493
  ISSN: 1438-1656
  DOI: 10.1002/adem.201500037
• Helmer H., Körner C., Singer R.:
  Additive manufacturing of nickel-based superalloy Inconel 718 by selective electron beam melting: Processing window and microstructure
  In: Journal of Materials Research 29 (2014), p. 1987-1996
  ISSN: 0884-2914
  DOI: 10.1557/jmr.2014.192
• Körner C., Helmer H., Bauereiß A., Singer R.:
  Tailoring the grain structure of IN718 during selective electron beam melting
  2nd European Symposium on Superalloys and Their Applications, EUROSUPERALLOYS 2014 (Giens)
  DOI: 10.1051/matecconf/20141408001
• Jüchter V., Scharowsky T., Singer R., Körner C.:
  Processing window and evaporation phenomena for Ti-6Al-4V produced by selective electron beam melting
  In: Acta Materialia 76 (2014), p. 252-258
  ISSN: 1359-6454
  DOI: 10.1016/j.actamat.2014.05.037
• Schwerdtfeger J., Körner C.:
  Selective electron beam melting of Ti-48Al-2Nb-2Cr: Microstructure and aluminium loss
  In: Intermetallics 49 (2014), p. 29-35
  ISSN: 0966-9795
  DOI: 10.1016/j.intermet.2014.01.004
• Hrabe NW., Heinl P., Bordia RK., Körner C., Fernandes RJ.:
  Maintenance of a bone collagen phenotype by osteoblast-like cells in 3D periodic porous titanium (Ti-6Al-4 V) structures fabricated by selective electron beam melting
  In: Connective Tissue Research 54 (2013), p. 351-360
  ISSN: 0300-8207
  DOI: 10.3109/03008207.2013.822864
• Wieding J., Fritsche A., Heinl P., Körner C., Matthias C., Seitz H., Mittelmeier W., Bader R.:
  Biomechanical behavior of bone scaffolds made of additive manufactured tricalciumphosphate and titanium alloy under different loading conditions
  In: Journal of Applied Biomaterials and Fundamental Materials 11 (2013), p. 159-166
  ISSN: 2280-8000
  DOI: 10.5301/JABFM.2013.10832
• Arkudas A., Galyna P., Beier J., Weigel L., Körner C., Singer R., Bleiziffer O., Polykandriotis E., Horch RE., Kneser U.:
  Combination of extrinsic and intrinsic pathways significantly accelerates axial vascularization of bioartificial tissues
  In: Plastic and Reconstructive Surgery 129 (2012), p. 55e-65e
  ISSN: 0032-1052
  DOI: 10.1097/PRS.0b013e3182361f97
• Hrabe NW., Heinl P., Flinn B., Körner C., Bordia RK.:
  Compression-compression fatigue of selective electron beam melted cellular titanium (Ti-6Al-4V)
  In: Journal of Biomedical Materials Research Part B-Applied Biomaterials (2011), p. 313-320
  ISSN: 1552-4973
  DOI: 10.1002/jbm.b.31901
• Ponader S., von Wilmowsky C., Widenmayer M., Lutz R., Heinl P., Körner C., Singer R., Nkenke E., Neukam FW., Schlegel K.:
  In vivo performance of selective electron beam-melted Ti-6Al-4V structures
  In: Journal of Biomedical Materials Research Part A 92 (2010), p. 56-62
  ISSN: 1549-3296
  DOI: 10.1002/jbm.a.32337
• Heinl P., Müller L., Körner C., Singer R., Müller F.:
  Cellular Ti-6Al-4V structures with interconnected macro porosity for bone implants fabricated by selective electron beam melting
  In: Acta Biomaterialia 4 (2008), p. 1536-1544
  ISSN: 1742-7061
  DOI: 10.1016/j.actbio.2008.03.013
• Ponader S., Vairaktaris E., Heinl P., von Wilmowsky C., Rottmair A., Körner C., Singer R., Holst S., Schlegel K., Neukam FW., Nkenke E.:
  Effects of topographical surface modifications of electron beam melted Ti-6Al-4V titanium on human fetal osteoblasts
  In: Journal of Biomedical Materials Research Part A 84 (2008), p. 1111-1119
  ISSN: 1549-3296
  DOI: 10.1002/jbm.a.31540
• Heinl P., Körner C., Singer R.:
  Mechanically Adapted Cellular Titanium for Bone Substitution
  International Symposium on Cellular Metals for Structural and Functional Applications 2008 (Dresden)
• Heinl P., Körner C., Singer R.:
  Selective electron beam melting - A novel generative manufacturing technique for cellular titanium
  5th International Conference on Porous Metals and Metallic Foams, MetFoam 2007 (Montreal, QC)
  URL: https://www.scopus.com/inward/record.uri?partnerID=HzOxMe3b&scp=56549129261&origin=inward
• Heinl P., Körner C., Singer R.:
  Selective electron beam melting of cellular titanium: Mechanical properties
  In: Advanced Engineering Materials 10 (2008), p. 882-888
  ISSN: 1438-1656
  DOI: 10.1002/adem.200800137
• Heinl P., Rottmair A., Körner C., Singer R.:
  Cellular titanium by selective electron beam melting
  In: Advanced Engineering Materials 9 (2007), p. 360-364
  ISSN: 1438-1656
  DOI: 10.1002/adem.200700025
• Fink A., Fu Z., Körner C.:
  Functional properties and shape memory effect of Nitinol manufactured via electron beam powder bed fusion
  In: Materialia 30 (2023), Article No.: 101823
  ISSN: 2589-1529
  DOI: 10.1016/j.mtla.2023.101823
• Reith M., Franke M., Körner C.:
  Impact of the acceleration voltage on the processing of γ-TiAl via electron beam powder bed fusion
  In: Progress in Additive Manufacturing (2023)
  ISSN: 2363-9512
  DOI: 10.1007/s40964-023-00499-4
• Yang J., Fu Z., Wahl L., Travitzky N., Körner C.:
  Correlation Between Structural Features and Magnetic Performance of Fe93.5Si6.5 (wt.%) Soft Magnetic Materials
  In: Advanced Functional Materials (2023)
  ISSN: 1616-301X
  DOI: 10.1002/adfm.202308194
• Zallmann S., Fu Z., Körner C.:
  Powder sintering kinetics during electron beam based additive manufacturing
  In: Powder Technology 434 (2024), Article No.: 119332
  ISSN: 0032-5910
  DOI: 10.1016/j.powtec.2023.119332
• Yang J.:
  Electron beam-based additive manufacturing of Fe-Si soft magnetic materials (Dissertation, 2024)
• Knörlein J.:
  Elektronenstrahlbasierte additive Fertigung von Titanaluminid-Bauteilen mit dualer Mikrostruktur (Dissertation, 2024)
• Ye J., Chen T., Körner C.:
  Correlating outgassing and smoke phenomenon in electron beam powder bed fusion of Ti6Al4V using a residual gas analyzer
  In: Progress in Additive Manufacturing (2024)
  ISSN: 2363-9512
  DOI: 10.1007/s40964-024-00745-3