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| Naji, M. |
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| Motta, Antonella |
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| Aletan, Dirar |
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| Mohamed, Tarek |
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| Ertürk, Emre |
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| Taccardi, Nicola |
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| Kononenko, Denys |
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| Petrov, R. H. | Madrid |
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| Alshaaer, Mazen | Brussels |
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| Bih, L. |
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| Casati, R. |
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| Muller, Hermance |
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| Kočí, Jan | Prague |
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| Šuljagić, Marija |
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| Kalteremidou, Kalliopi-Artemi | Brussels |
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| Azam, Siraj |
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| Ospanova, Alyiya |
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| Blanpain, Bart |
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| Ali, M. A. |
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| Popa, V. |
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| Rančić, M. |
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| Ollier, Nadège |
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| Azevedo, Nuno Monteiro |
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| Landes, Michael |
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| Rignanese, Gian-Marco |
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Haubrich, Jan
in Cooperation with on an Cooperation-Score of 37%
Topics
Publications (27/27 displayed)
- 2024Elucidating the challenges in the development and deployment of refractory complex concentrated alloys for additive manufacturingcitations
- 2024Elucidating the challenges in the development and deployment of refractory complex concentrated alloys for additive manufacturingcitations
- 2024Evolution of interphase stress over a crack propagation plane as a function of stress relief heat treatments in a PBF‐LB/M AlSi10Mg alloycitations
- 2024Changes in the morphology and chemistry of an oxidation-sensitive beta-Ti alloy powder during the processing steps of additive manufacturing
- 2024Enhancing surface quality of LPBF-manufactured aerospace components through chemical etching and non-destructive evaluation
- 2024Damage monitoring of pinned hybrid composite–titanium joints using direct current electrical resistance measurementcitations
- 2024Fuel Thermal Management and Injector Part Design for LPBF Manufacturing
- 2024NON-DESTRUCTIVE ANALYSIS OF CHEMICAL TREATMENT OF INTERNAL SHAPED CHANNELS IN LPBF INCONEL 718
- 2024LASER POWDER BED FUSION AND TESTING OF COMPRESSOR WHEELS FROM Gamma-TITANIUM ALUMINIDE TI48-2-2
- 2023Microstructure formation during laser powder bed fusion of Ti-22Al-25Nb with low and high pre-heating temperaturescitations
- 2023Strategies to accelerate the design, discovery, development and deployment of materials in the era of the digital transformation
- 2023Adhesion properties of the hybrid system made of laser-structured aluminium EN AW 6082 and CFRP by co-bonding-pressing processcitations
- 2021In Situ High‐Energy Synchrotron X‐Ray Diffraction Reveals the Role of Texture on the Activation of Slip and Twinning during Deformation of Laser Powder Bed Fusion Ti–6Al–4Vcitations
- 2021Interface‐Mediated Twinning‐Induced Plasticity in a Fine Hexagonal Microstructure Generated by Additive Manufacturingcitations
- 2020Ultrafine eutectic Ti-Fe-based alloys processed by additive manufacturing – A new candidate for high temperature applicationscitations
- 2020Ultrafine eutectic Ti-Fe-based alloys processed by additive manufacturing – A new candidate for high temperature applicationscitations
- 2020Ultrafine Fe-Fe2Ti eutectics by directed energy deposition: Insights into microstructure formation based on experimental techniques and phase field modellingcitations
- 2020Mapping the geometry of Ti-6Al-4V: From martensite decomposition to localized spheroidization during selective laser meltingcitations
- 2019Topology Optimization of a Star Tracker Camera Bracket
- 2018New aspects about the search for the most relevant parameters optimizing SLM materialscitations
- 2018Buried interfaces – A systematic study to characterize an adhesive interface at multiple scalescitations
- 2018Subsurface residual stress analysis in Ti-6Al-4V additive manufactured parts by synchrotron x-ray diffraction
- 2018Buried interfaces -a systematic study to characterize an adhesive interface at multiple scalescitations
- 2017Inducing Stable $alpha$ + $beta$ Microstructures during Selective Laser Melting of Ti-6Al-4V Using Intensified Intrinsic Heat Treatmentscitations
- 2017Using metastability to engineer the microstructure of Ti-6V-4Al produced by selective laser melting
- 2017Inducing Stable alpha plus beta Microstructures during Selective Laser Melting of Ti-6Al-4V Using Intensified Intrinsic Heat Treatmentscitations
- 2007Adsorption and Selective Hydrogenation of α, β-unsaturated Aldehydes on Pt(111) and Pt-Sn Model Catalysts
Places of action
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document
Topology Optimization of a Star Tracker Camera Bracket
Abstract
Topology optimization is a powerful tool in lightweight design and has become increasingly popular with recent advances in additive manufacturing (AM). In the space industry, optimized and 3D-printed structures have the potential to meet the increasing demand for cost-efficient, flexible design and manufacturing strategies driven by large satellite constellations. In this paper a case study for re-designing a satellite structure is presented, identifying and exploring challenges and opportunities throughout the entire process chain. The reference part for this study is a star tracker camera bracket from the academic satellite Flying Laptop from the University of Stuttgart, currently operating in orbit. The original part was manufactured using standard machining processes and is used for functional as well as the cost reference of the AM optimization and manufacturing approach. The first step of the investigation is a characterization of AlSi10Mg manufactured by Laser Powder Bed Fusion (LPBF), focusing on the demands for topology optimization and associated cost-intensive post processing. Mechanical and metallographic properties for different sample geometries, orientations and heat treatments have been analyzed. This data provides the input for the material model in the optimization process as well as the optimization constraints. Following this step, the mesh-based optimization result is converted to a CAD geometry to assess manufacturability. For validation and cost assessment, the bracket is printed three times in one build-job using a Trumpf TruPrint 3000. Printed brackets are assessed for their natural frequency, the dominant design constraint, as well as the geometrical distortion and compared to the analysis results. Finally, design and manufacturing costs of the single part and of a small series of 99 parts is calculated to evaluate economic potential of the optimized and printed design. For the reference part presented in this study, the optimized design is 30 % lighter than the original and exhibits a 43 % higher first natural frequency. Additionally, a considerable scaling effect on the manufacturing costs is shown, keeping additive manufacturing competitive compared to small series machining production.