Lehrstuhl für Fertigungstechnologie, Universität Erlangen-Nürnberg

Additive manufacturing of metal assemblies with formed sheet-body (DFG CRC 814)

Project Status: finished


Fundamental understanding of a new and innovative process combining, sheet metal forming with additive manufacturing, is the main goal of this research work. Within the first phase of the subproject B5 of the Collaborative Research Center 814 - Additive Manufacturing (CRC 814) it has been the aim to develop a process chain which allows manufacturing functional elements on deep drawn Ti‑6Al‑4V sheet-body parts. To gain fundamental knowledge about the effect of different stress states in the base plate on the additive manufacturing process, the second phase of the Collaborative Research Center 814 will add bending of Ti‑6Al‑4V sheet metal to the processes combined with additive manufacturing. Laser beam melting will be utilized as additive manufacturing process and applied before and after the bending operation in order to achieve hybrid manufactured parts, combining sheet metal forming and additive manufacturing. Advantages of both manufacturing technologies, such as the high geometrical flexibility of additive manufacturing and large scaled geometries achievable by sheet metal forming, will be merged.

The scientific focus of the research project is to investigate the interaction between thermomechanical stress and deformation and the interaction between additive manufacturing and forming. First of all, the influence of each manufacturing step on the following one is studied. Second, physical and microstructural correlations will be detected and decoded. Based on this knowledge limits and possibilities for the combination of sheet metal forming and additive manufacturing can be pointed out.

20180724 B5 Aussendarstellung Homepage

Schematic process chain for the combination of sheet metal forming and additive manufacturing - from sheet metal to hybrid part

In cooperation with the Institute of Photonic Technologies.

The project is carried on in phase 3.

Research Groups



    • Papke, T.; Huber, F.; Heimes, M.; Schmidt, M.; Merklein, M.:
      Charakterisierung der Umformbarkeit und mechanischen Eigenschaften von additiv gefertigtem Ti6Al4V.
      In: Lehrstuhl für Umformtechnik, Montanuniversität Leoben, Martin Stockinger (Edtrs.): XXXVIII. Verformungskundliches Kolloquium, 2019, pp. 101-106


    • Papke, T.; Junker, D.; Huber, F.; Hentschel, O.; Schmidt, M.; Merklein, M.:
      Verknüpfung additiver Fertigung und Umformtechnik in Form hybrider Bauteile und Werkzeuge.
      In: Witt, G. (Edtr.): Tagungsband Fachtagung Werkstoffe und Additive Fertigung, 2018, pp. 64-69

    • Papke, T.; Dubjella, P.; Butzhammer, L.; Huber, F.; Schmidt, M.; Merklein, M.:
      Influence of a bending operation on the bonding strength for hybrid parts made of Ti-6Al-4V.
      Procedia CIRP 74(2018), pp. 290-294

    • Papke, T.; Graser, M.; Merklein, M.:
      Numerical modelling approach for the temperature dependent forming behaviour of Ti-6Al-4V.
      In: Qin, Y.; Dean, T.A.; Lin, J.; Yuan, S. J.; Vollertsen, F. (Edtrs.): MATEC Web of Conferences, doi: 10.1051/matecconf/201819012004, 190, 2018, published online

    • Papke, T.; Junker, D.; Schmidt, M.; Kolb, T.; Merklein, M.:
      Bulk Metal Forming of Additively Manufactured Elements.
      In: Qin, Y.; Dean, T.A.; Lin, J.; Yuan, S. J.; Vollertsen, F. (Edtrs.): MATEC Web of Conferences, doi: https://doi.org/10.1051/matecconf/201819003002, 190, 2018, published online

    • Huber, F.; Papke, T.; Kerkien, M.; Tost, F.; Geyer, G.; Merklein, M.; Schmidt, M.:
      Customized Exposure Strategies for Manufacturing Hybrid Parts by Combining Laser Beam Melting and Sheet Metal Forming.
      Journal of Laser Applications, International Congress on Applications of Lasers & Electro-Optics (ICALEO), doi: https://doi.org/10.2351/1.5096115, 31(2018)2, published online

    • Papke, T.; Huber, F.; Geyer, G.; Schmidt, M.; Merklein, M.:
      Characterisation of the tensile bonding strength of Ti 6Al 4V hybrid parts made by sheet metal forming and laser beam melting.
      In: Schmitt, R.; Schuh, G. (Edtrs.): Advances in Production Research - Proceedings of the 8th Congress of the German Academic Association for Production Technology (WGP), 2018, pp. 361-370

    • Papke, T.; Huber, F.; Hagenah, H.; Schmidt, M.; Merklein, M.:
      Potentiale der Kombination von Umformtechnik und additiver Fertigung in hybriden Prozessketten.
      In: Drummer, D. (Edtr.): 6. Industriekolloquium des Sonderforschungsbereichs 814 - Additive Fertigung, Print Line, 2018, pp. 59-76

    • Huber, F.; Papke, T.; Scheitler, C.; Hanrieder, L.; Merklein, M.; Schmidt, M.:
      In Situ Formation of a Metastable beta-Ti Alloy by Laser Powder Bed Fusion (L-PBF) of Vanadium and Iron Modified Ti-6Al-4V.
      Metals 8(2018)1067, pp. 1-9


    • Dubjella, P.; Merklein, M.:
      Influence of Warm Bending on the Surface Topography of Titanium Alloy Ti-6Al-4V.
      Procedia Engineering 183(2017), pp. 23-30

    • Butzhammer, L.; Dubjella, P.; Huber, F.; Schaub, A.; Aumüller, M.; Baum, A.; Petrunenko, O.; Merklein, M.; Schmidt, M.:
      Experimental investigation of a process chain combining sheet metal bending and laser beam melting of Ti-6Al-4V.
      In: WLT e.V. (Edtr.): Lasers in Manufacturing Conference 2017, 2017, accepted


    • Schaub, A.; Degner, J.; Ahuja, B.; Schmidt, M.; Merklein, M.:
      Numerical Investigation for Superplastic Forming Tool Development Within the Combined Process Chain of Forming and Additive Manufacturing.
      In: Dimitrov, D; Oosthuizen, T. (Edtrs.): Int. Conf. Competitive Manufacturing, 2016, pp. 173-179

    • Merklein, M.; Junker, D.; Schaub, A.; Neubauer, F.:
      Hybrid Additive Manufacturing Technologies - An Analysis regarding Potentials and Applications.
      Procedia Engineering 83(2016), pp. 549 - 559

    • Schaub, A.; Bhrigu, A.; Butzhammer, L.; Osterziel, J.; Schmidt, M.; Merklein, M.:
      Additive manufacturing of functional elements on sheet metal.
      Physics Procedia 83(2016), pp. 797-807

    Letztes Update: 07.02.2020