@article{64678,
  abstract     = {{One of the major topics in the modern automotive industry is reducing emissions and increasing the mileage
range. To tackle this challenge, on the one hand, modifying the powertrain system is a possibility, and on the
other hand, lightweight design offers various possibilities. Multi-Material Design (MMD) involves designing car
bodies that combine different materials that require joining. Given the variety of materials, mechanical joining
processes are preferred. Especially the current development of the Giga/Mega-casting process concerning
aluminium casting and the subsequent mechanical joining illustrates the challenges of this material group. In car
production, aluminium castings are mainly made from aluminium-silicon (AlSi) alloys. Ultimately, the alloy
system's insufficient ductility leads to crack initiation during mechanical joining. Cast parts are therefore often
used in areas of the car body that are exposed to high-pressure loads. For example, self-piercing riveting (SPR) is
used due to its high load-bearing capacity. In this study, improved joinability is demonstrated by influencing the
microstructure through tailored solidification rates and a developed heat-treatment chain strategy adapted for
hypoeutectic AlSi systems. Data on microstructure, mechanical, and joining properties are used to develop a
solidification-joining correlation for the SPR process across a range of Si contents and solidification rates. The
purpose is to develop the ability to produce suitable aluminium castings with sufficient joinability, thereby
improving versatility.}},
  author       = {{Neuser, Moritz and Kaimann, Pia Katharina and Stratmann, Ina and Bobbert, Mathias and Klöckner, Johann Moritz Benedikt and Mann, Moritz and Hoyer, Kay-Peter and Meschut, Gerson and Schaper, Mirko}},
  journal      = {{Journal of Manufacturing Processes}},
  keywords     = {{Mechanical joining, Aluminium, Self-piercing riveting, Casting, Microstructure, Joinability AlSi-alloys}},
  publisher    = {{Elsevier}},
  title        = {{{Solidification-joinability correlation of hypoeutectic aluminium casting alloys for self-piercing riveting (SPR)}}},
  doi          = {{https://doi.org/10.1016/j.jmapro.2026.02.040}},
  volume       = {{164}},
  year         = {{2026}},
}

@article{59872,
  abstract     = {{Lightweight design is a driving concept in modern automotive engineering to minimize resource consumption over a vehicle's lifecycle through multi-material design, which relies on the use of joining techniques in car body fabrication. Multi-material design and the increasing trend towards producing large structural components using the megacasting process pose considerable challenges, particularly in the mechanical joining of aluminium-silicon (AlSi) castings. These castings typically exhibit low ductility and are prone to cracking when mechanically joined. Based on the excellent castability of hypoeutectic AlSi alloys, these are applied in sand casting and die casting as well as in megacasting. With a silicon content between 7 wt% and 12 wt%, these AlSi-alloys have a plate-like silicon phase that initiates cracks during mechanical joining. To enhance the joinability of castings, the research hypothesis is that improved solidification conditions enable a significant modification in the microstructure and therefore, increase the mechanical properties. During the manufacture of the castings using the sand casting process, the solidification conditions within the structural elements are varied to modify the microstructure to obtain castings with graded microstructure. The castings are evaluated using mechanical, microstructural and joining testing methods and finally, a microstructure-joinability correlation is established.}},
  author       = {{Neuser, Moritz and Schlichter, Malte Christian and Hoyer, Kay-Peter and Bobbert, Mathias and Meschut, Gerson and Schaper, Mirko}},
  journal      = {{44th Conference of the International Deep Drawing Research Group (IDDRG 2025)}},
  keywords     = {{Joining, Casting, Self-pierce riveting, Aluminium casting alloy}},
  location     = {{Lissabon (Portugal)}},
  title        = {{{Mechanical joinability of microstructurally graded structural components manufactured from hypoeutectic aluminium casting alloys}}},
  doi          = {{10.1051/matecconf/202540801081}},
  volume       = {{408}},
  year         = {{2025}},
}

@article{58133,
  author       = {{Pramanik, Sudipta and Mileaege, Dennis and Andreiev, Anatolii and Hoyer, Kay-Peter and Schaper, Mirko}},
  issn         = {{1059-9495}},
  journal      = {{Journal of Materials Engineering and Performance}},
  publisher    = {{Springer Science and Business Media LLC}},
  title        = {{{Effect of Compression Rate and Pore Size Distribution on the Compression Behavior of Additively Manufactured Bio-inspired Fe3Si Microporous Material}}},
  doi          = {{10.1007/s11665-024-10618-z}},
  year         = {{2025}},
}

@article{58807,
  abstract     = {{One of the most important strategies for reducing CO2 emissions in the mobility sector is lightweight construction. In particular, the car body offers several opportunities for weight reduction. Multi-material designs are increasingly being applied to select the most suitable material for the respective load and ultimately achieve synergy effects. For example, aluminium castings are used at the nodes of a spaceframe body. Subsequently, these are joined with profiles to form the bodyshell. To join different materials mechanical joining techniques, such as semi-tubular self-piercing riveting, are deployed. According to the current state of the art, cracks occur in the aluminium castings during the mechanical joining process as a result of the high degree of deformation. Although the aluminium casting alloys of the AlSi-system exhibit low ductility, these alloys reveal excellent castability. In particular, the ability to cast thin structural parts is enabled by the low liquidus point of the near eutectic aluminium casting alloys.
This study addresses the mechanical joining properties of the near eutectic aluminium casting alloy AlSi12, depending on different microstructures. These are achieved by annealing processes and modifying agents. Through an adapted heat treatment, the previously lamellar morphology can be transformed into a globular morphology, which leads to increased ductility and prevents the formation of cracks during the self-piercing riveting (SPR). The joinability is investigated using different die geometries, whereas the joint formation is analysed regarding crack initiation. To evaluate the increased ductility, microstructural and mechanical tests are performed and finally, a microstructure-joinability correlation is established.}},
  author       = {{Neuser, Moritz and Holtkamp, Pia Katharina and Hoyer, Kay-Peter and Kappe, Fabian and Yildiz, Safak and Bobbert, Mathias and Meschut, Gerson and Schaper, Mirko}},
  journal      = {{The Journal of Materials: Design and Applications, Part L}},
  keywords     = {{aluminium, casting, microstructure, joinability, self-piercing riveting}},
  location     = {{Porto, Portugal}},
  publisher    = {{Sage Publications}},
  title        = {{{Mechanical properties and joinability of the near-eutectic aluminium casting alloy AlSi12}}},
  doi          = {{10.1177/14644207251319922}},
  year         = {{2025}},
}

@inbook{58950,
  author       = {{Braun, Marcel Patrick Klaus and Grydin, Olexandr and Hoyer, Kay-Peter and Schaper, Mirko}},
  booktitle    = {{The Minerals, Metals & Materials Series}},
  isbn         = {{9783031810602}},
  issn         = {{2367-1181}},
  location     = {{LAs Vegas, USA}},
  publisher    = {{Springer Nature Switzerland}},
  title        = {{{Precipitation Hardening in the Magnesium–Zinc–Calcium Alloy System}}},
  doi          = {{10.1007/978-3-031-81061-9_12}},
  year         = {{2025}},
}

@inproceedings{59154,
  abstract     = {{<jats:p>Abstract. Lightweight design is one of the central topics of the automotive industry since reducing mass can save emissions over the entire life cycle of a component. Nowadays, vehicle structures usually consist of a multi-material design, which poses the additional challenge of joining these different materials. Mechanical joining is the most common way of joining different types of materials. Cast aluminium alloys of the AlSi system have a low ductility, which causes cracks during the mechanical joining process in the joint. One research approach is to achieve a fine microstructure by influencing the solidification rate since this results in increased mechanical properties, specifically the elongation at fracture and yield strength. A very fine microstructure can be achieved by utilizing Twin-roll casting (TRC) which is a continuous casting process in which high solidification rates of more than 100 K/s occur. In this study, the hypoeutectic cast aluminium alloy AlSi9 is processed in the TRC process using copper rollers. The cast strips are investigated regarding the microstructure-property correlation. A variation of the roller materials and cooling conditions allows for an increase in the solidification rate, whereby a defined, fine microstructure can be achieved, which enhances the mechanical properties of the hypoeutectic aluminium casting alloys.</jats:p>}},
  author       = {{Neuser, Moritz and Hoyer, Kay-Peter and Schaper, Mirko}},
  booktitle    = {{Materials Research Proceedings}},
  issn         = {{2474-395X}},
  publisher    = {{Materials Research Forum LLC}},
  title        = {{{Processing of the hypoeutectic AlSi9 alloy with twin-roll casting by using copper shells}}},
  doi          = {{10.21741/9781644903551-26}},
  volume       = {{52}},
  year         = {{2025}},
}

@inproceedings{59155,
  abstract     = {{<jats:p>Abstract. Twin-Roll-Casting (TRC) is an energy- and cost-efficient process to produce near-net-shape aluminum strips. Due to the high affinity of molten aluminum to steel surfaces, those rollers show signs of wear throughout the rolling campaign. This leads to the necessity of restoring the worn surfaces to suitable parameters. The easiest way is to grind the surface till all superficial defects are omitted. However, the thickness of the roller is not endless, therefore the rollers must be replaced after a certain amount of surface reconditioning. This ultimately leads to the non-usability of the roller. This research shows a route to recondition the surface including the possibility of renewing worn-down surfaces with an energy- and cost-efficient high-velocity oxygen fuel (HVOF) treatment with subsequent grinding to the desired initial surface parameters.</jats:p>}},
  author       = {{Lauth, Martin and Hoyer, Kay-Peter and Schaper, Mirko and Gräfen, Winfried}},
  booktitle    = {{Materials Research Proceedings}},
  issn         = {{2474-395X}},
  publisher    = {{Materials Research Forum LLC}},
  title        = {{{Cost-effective repair solution for twin-roll-caster rollers}}},
  doi          = {{10.21741/9781644903551-5}},
  volume       = {{52}},
  year         = {{2025}},
}

@article{60851,
  author       = {{Ghosh, Koustav and Milaege, Dennis and Steinmeier, Paul and Schaper, Mirko and Hoyer, Kay-Peter and Pramanik, Sudipta}},
  issn         = {{1059-9495}},
  journal      = {{Journal of Materials Engineering and Performance}},
  publisher    = {{Springer Science and Business Media LLC}},
  title        = {{{Effect of Strain Rate on the Deformation Behavior and Energy Absorption Characteristics of LPBF-Processed Ti2448 Microarchitectured Lattice Structures}}},
  doi          = {{10.1007/s11665-025-11669-6}},
  year         = {{2025}},
}

@article{62160,
  abstract     = {{<jats:p>Laser powder bed fusion is a cornerstone technology for additive manufacturing (AM) of metals and polymers, yet challenges in achieving consistent reproducibility and process optimization persist. Addressing these requires a systematic understanding of the interactions between feedstock, process parameters, and final part characteristics throughout the entire production chain. This study presents results from a comprehensive interlaboratory investigation conducted by 32 research institutions, evaluating six feedstock, including nanoparticle‐modified aluminum alloy and polyamide powders, under standardized protocols. Data analysis encompasses 69 powder properties, 15 process parameters per print, and 78 part features, culminating in a dataset of over 1.2 million correlations. Advanced statistical methods and machine learning are employed to identify critical variability drivers, such as the impact of nanoparticle modifications on powder flowability and thermal conductivity, as well as the influence of process parameters on reproducibility. Newly introduced dimensionless figures of merit provide universal metrics to describe and predict thermal and mechanical interactions, simplifying process optimization and material characterization. The findings, supported by an open‐access dataset adhering to findable, accessible, interoperable, and reusable principles, advance understanding of material–process–structure–property relationships. They establish a benchmark for future research and lay the foundation for improving the reliability, quality, and sustainability of AM processes.</jats:p>}},
  author       = {{Kuşoğlu, Ihsan Murat and Garg, Sunidhi and Abel, Arvid and Balachandran, Prasanna V. and Barcikowski, Stephan and Becker, Louis and Bernsmann, Jan-Simeon and Boseila, Jonas and Broeckmann, Christoph and Coskun, Mert and Dreyer, Malte and East, Mark and Easton, Mark and Ellendt, Nils and Gann, Stan and Gökce, Bilal and Goßling, Mareen and Greiner, Joachim and Gruber, Piotr and Grünewald, Moritz and Gurung, Kopila and Hantke, Nick and Hengsbach, Florian and Holländer, Hannes and Van Hooreweder, Brecht and Hoyer, Kay-Peter and Huang, Yajiang and Huber, Florian and Kessler, Olaf and Kısasöz, Burçin Özbay and Kleszczynski, Stefan and Koc, Ebubekir and Kurzynowski, Tomasz and Kwade, Arno and Leupold, Simon and Liu, Dongmei and Lomo, Felix and Lüddecke, Arne and Luinstra, Gerrit A. and Mauchline, David A. and Meyer, Fabian and Meyer, Lars and Middendorf, Peter and Nolte, Stefan and Olejarczyk, Michał and Overmeyer, Ludger and Pich, Andrij and Platt, Sebastian and Radtke, Felix and Ramm, Roland and Rittinghaus, Silja-Katharina and Rothfelder, Richard and Rudloff, Johannes and Schaper, Mirko and Scheck, Marie Luise and Schleifenbaum, Johannes Henrich and Schmidt, Michael and Sehrt, Jan T. and Shabanga, Yvonne P. and Sommereyns, Alexander and Steuer, Rabea and Tisha, Layla Shams and Toenjes, Anastasiya and Tuck, Christopher and Vaghar, Adrian and Vrancken, Bey and Wang, Zhengze and Weber, Sebastian and Wegner, Jan and Xu, Bai-Xiang and Yang, Yangyiwei and Zhang, Duyao and Zhuravlev, Evgeny and Ziefuss, Anna R.}},
  issn         = {{1438-1656}},
  journal      = {{Advanced Engineering Materials}},
  number       = {{14}},
  publisher    = {{Wiley}},
  title        = {{{Large‐Scale Interlaboratory Study Along the Entire Process Chain of Laser Powder Bed Fusion: Bridging Variability, Standards, and Optimization across Metals and Polymers}}},
  doi          = {{10.1002/adem.202402930}},
  volume       = {{27}},
  year         = {{2025}},
}

@inproceedings{62725,
  abstract     = {{Aluminium-Silizium-Legierungen (AlSi) werden insbesondere bei der gießtechnischen
Herstellung von Leichtbaukomponenten für Fahrzeuge verwendet. Dieses Legierungssystem hat hervorragende
Gießeigenschaften bei gleichzeitig akzeptablen mechanischen Eigenschaften. Aufgrund des hohen
Silizium-(Si)-Gehaltes, wodurch die Volumenkontraktion im Phasenübergang von flüssig-fest nahezu
unterbunden wird, neigen AlSi-Legierungen dazu, feinere oder gröbere Si-Platten bei unterschiedlichen
Erstarrungsgeschwindigkeiten zu bilden. Um die mechanischen Eigenschaften zu verbessern, werden
dem Legierungssystem in der Schmelzphase entweder Natrium (Na) oder Strontium (Sr) zugesetzt. Dies
hat zur Folge, dass sich eine fein lamellare Si-Morphologie bei der Erstarrung ausbildet; dies kann ebenfalls
durch hohe Erstarrungsgeschwindigkeiten erreicht werden. Ein nachfolgendes Lösungsglühen bewirkt
eine Sphäroidisierung der Si-Partikel und dient der Steigerung der Duktilität. Aktuell fehlen fundierte
Erkenntnisse zur Ausprägung der Si-Morphologie in Abhängigkeit der Erstarrungsgeschwindigkeit oder
infolge einer Wärmebehandlung. Vor diesem Hintergrund werden in dieser Studie verschiedene Behandlungsparameter
in Bezug auf das Einformverhalten der Si-Partikel mit einem bildauswertenden Verfahren
evaluiert sowie unter Bezug auf verschiedene chemische Zusammensetzungen miteinander korreliert.}},
  author       = {{Neuser, Moritz and Cichon, Gerrit and Hoyer, Kay-Peter and Schaper, Mirko}},
  booktitle    = {{Bildauswertendes Verfahren zur Evaluierung der Mikrostruktur von AlSi-Systemen}},
  isbn         = {{978-3-88355-454-9}},
  keywords     = {{Bildauswertendes Verfahren, Mikrostrukturanalyse, AlSi-System, Si-Morphologie}},
  location     = {{Dresden}},
  pages        = {{454 -- 459}},
  publisher    = {{Deutsche Gesellschaft für Materialkunde (DGM)}},
  title        = {{{Bildauswertendes Verfahren zur Evaluierung der Mikrostruktur von AlSi-Systemen}}},
  volume       = {{43}},
  year         = {{2025}},
}

@techreport{63209,
  abstract     = {{Die DFG-Projekte AddFeRo-PM (406108415) und AddFeRo-SR (465089065) untersuchten die Potenziale des LB-PBF/M-Verfahrens zur Herstellung von Rotoren für unterschiedliche elektrische Maschinen. Im interdisziplinären Ansatz wurden Materialentwicklung und mechanische sowie elektromagnetische Optimierung verbunden. Im Projekt „AddFeRo-PM“ wurde der Rotor einer permanentmagneterregten Synchron- maschine (PMSM) untersucht. FeSi erwies sich als geeignete Legierung, konnte aber wegen Spannungsrissen nur bis zu 3 % Siliziumanteil (kurz: FeSi3) verarbeitet werden. Mechanische und elektromagnetische Untersuchungen ermöglichten eine 3D-Optimierung der Rotorgeometrie und -struktur. Der Demonstrator wurde additiv gefertigt und zeigt Leicht-baupotenziale sowie reduzierte Drehmomentwelligkeit. Im Folgeprojekt „AddFeRo-SR“ kam eine Hochtemperatur-Bauraumheizung (HTBH) zum Einsatz, die FeSi mit 6,5 % Siliziumanteil verarbeitbar machte, welches bessere elektro- magnetische Eigenschaften bietet. Sie wurde bei einer Synchron-Reluktanzmaschine (SynRM) getestet. Eine hybride Rotorfertigung erwies sich jedoch aufgrund von HTBH-Einschränkungen als ungeeignet, weshalb eine einteilige Fertigung mit FeSi3 umgesetzt wurde. Experimente bestätigten vergleichbare Betriebsergebnisse zur konventionellen Fertigung bei reduzierter Rotormasse. Zusätzlich wurde eine Methodik entwickelt, um additive Verfahren als Ergänzung zur konventionellen Fertigung zu integrieren. Beide Projekte zeigen das Potenzial additiver Fertigung für Leichtbau und Wirkungsgradsteigerung im Elektromaschinenbau und bieten wertvolle Grundlagen für industrielle Anwendungen.}},
  author       = {{Haase, Michael and Behrendt, Marius and Hengsbach, Florian and Kunnathully Sathees Kumar, Vinay and Magerkohl, Sebastian and Magyar, Balázs and Ponick, Bernd and Schaper, Mirko and Zimmer, Detmar}},
  keywords     = {{Additive Fertigung, Elektromotor, Leichtbau, Synchronmotor, DFG}},
  publisher    = {{Technische Informationsbibliothek}},
  title        = {{{Additive Fertigung im Elektromaschinenbau: Erforschung von Potentialen der additiven Fertigung in Rotoren permanentmagneterregter Synchronmaschinen}}},
  doi          = {{10.34657/26753}},
  year         = {{2025}},
}

@article{52738,
  abstract     = {{<jats:p>Through tailoring the geometry and design of biomaterials, additive manufacturing is revolutionizing the production of metallic patient-specific implants, e.g., the Ti-6Al-7Nb alloy. Unfortunately, studies investigating this alloy showed that additively produced samples exhibit anisotropic microstructures. This anisotropy compromises the mechanical properties and complicates the loading state in the implant. Moreover, the minimum requirements as specified per designated standards such as ISO 5832-11 are not met. The remedy to this problem is performing a conventional heat treatment. As this route requires energy, infrastructure, labor, and expertise, which in turn mean time and money, many of the additive manufacturing benefits are negated. Thus, the goal of this work was to achieve better isotropy by applying only adapted additive manufacturing process parameters, specifically focusing on the build orientations. In this work, samples orientated in 90°, 45°, and 0° directions relative to the building platform were manufactured and tested. These tests included mechanical (tensile and fatigue tests) as well as microstructural analyses (SEM and EBSD). Subsequently, the results of these tests such as fractography were correlated with the acquired mechanical properties. These showed that 90°-aligned samples performed best under fatigue load and that all requirements specified by the standard regarding monotonic load were met.</jats:p>}},
  author       = {{Milaege, Dennis and Eschemann, Niklas and Hoyer, Kay-Peter and Schaper, Mirko}},
  issn         = {{2073-4352}},
  journal      = {{Crystals}},
  keywords     = {{Inorganic Chemistry, Condensed Matter Physics, General Materials Science, General Chemical Engineering}},
  number       = {{2}},
  publisher    = {{MDPI AG}},
  title        = {{{Anisotropic Mechanical and Microstructural Properties of a Ti-6Al-7Nb Alloy for Biomedical Applications Manufactured via Laser Powder Bed Fusion}}},
  doi          = {{10.3390/cryst14020117}},
  volume       = {{14}},
  year         = {{2024}},
}

@article{57540,
  abstract     = {{<jats:title>Abstract</jats:title><jats:p>Rolling processes of conventional cast Al-Li alloys quickly reach their limits due to relatively poor material formability. This can be overcome by using twin-roll casting to produce thin sheets. Further thermomechanical treatment, including hot or cold rolling, and heat treatment can adjust the mechanical properties of twin-roll cast Al-Li sheets. The whole manufacturing chain requires detailed knowledge of the precipitation and dissolution behavior during heating, soaking and cooling, to purposefully select any process parameters. This study shows the process chain of a twin-roll cast Al–Cu–Li alloy achieving a hardness of around 180 HV1 by adapting the heat treatment parameters for homogenisation, hot rolling and age hardening. Both hardness and microstructure evolution are visualised along the process chain.</jats:p>}},
  author       = {{Mallow, Sina and Broer, Jette and Milkereit, Benjamin and Grydin, Olexandr and Hoyer, Kay-Peter and Garthe, Kai-Uwe and Milaege, Dennis and Boyko, Viktoriya and Schaper, Mirko and Kessler, Olaf}},
  issn         = {{0944-6524}},
  journal      = {{Production Engineering}},
  publisher    = {{Springer Science and Business Media LLC}},
  title        = {{{Process chain of a twin-roll cast aluminium-copper-lithium alloy}}},
  doi          = {{10.1007/s11740-024-01322-x}},
  year         = {{2024}},
}

@article{49107,
  abstract     = {{<jats:p>The effect of plaque deposition (atherosclerosis) on blood flow behaviour is investigated via computational fluid dynamics and structural mechanics simulations. To mitigate the narrowing of coronary artery atherosclerosis (stenosis), the computational modelling of auxetic and non-auxetic stents was performed in this study to minimise or even avoid these deposition agents in the future. Computational modelling was performed in unrestricted (open) conditions and restricted (in an artery) conditions. Finally, stent designs were produced by additive manufacturing, and mechanical testing of the stents was undertaken. Auxetic stent 1 and auxetic stent 2 exhibit very little foreshortening and radial recoil in unrestricted deployment conditions compared to non-auxetic stent 3. However, stent 2 shows structural instability (strut failure) during unrestricted deployment conditions. For the restricted deployment condition, stent 1 shows a higher radial recoil compared to stent 3. In the tensile test simulations, short elongation for stent 1 due to strut failure is demonstrated, whereas no structural instability is noticed for stent 2 and stent 3 until 0.5 (mm/mm) strain. The as-built samples show a significant thickening of the struts of the stents resulting in short elongations during tensile testing compared to the simulations (stent 2 and stent 3). A modelling framework for the stent deployment system that enables the selection of appropriate stent designs before in vivo testing is required. This leads to the acceleration of the development process and a reduction in time, resulting in less material wastage. The modelling framework shall be useful for doctors designing patient-specific stents.</jats:p>}},
  author       = {{Pramanik, Sudipta and Milaege, Dennis and Hein, Maxwell and Hoyer, Kay-Peter and Schaper, Mirko}},
  issn         = {{2073-4352}},
  journal      = {{Crystals}},
  keywords     = {{Inorganic Chemistry, Condensed Matter Physics, General Materials Science, General Chemical Engineering}},
  number       = {{11}},
  publisher    = {{MDPI AG}},
  title        = {{{Additive Manufacturing and Mechanical Properties of Auxetic and Non-Auxetic Ti24Nb4Zr8Sn Biomedical Stents: A Combined Experimental and Computational Modelling Approach}}},
  doi          = {{10.3390/cryst13111592}},
  volume       = {{13}},
  year         = {{2023}},
}

@inproceedings{43031,
  abstract     = {{<jats:p>Abstract. Requirements of multi-material construction involve adjustments to standard joining techniques. Especially the growing importance of integral cast components poses additional engineering challenges for the industry. One approach to achieve these goals are adaptable joining elements formed by friction spinning. This approach uses friction-induced heat to form customisable joining elements to join sheets for different boundary conditions, even for brittle cast materials. It is possible to react immediately to adapt to the joining process inline and reduce the amount of different joining elements. As the joining partner serve casting plates of the aluminium casting alloy EN AC–AlSi9, which is processed in the sand casting. Joining hypoeutectic AlSi alloys constitutes a challenge because the brittle character of these cause cracks in the joint during conventional mechanical joining. Furthermore, the friction-induced heat of the novel joining process causes a finer microstructure in the hypoeutectic AlSi9 casting alloy. In particular, the eutectic Si is more fine-grained, resulting in higher joint ductility. This study indicates the joining suitability of a hypoeutectic aluminium casting alloy in combination with adaptive manufactured additional joining elements. Here, various mechanical and microstructural investigations validate the influence of the thermomechanical joining technique. In conclusion, the potential of this joining process is presented regarding the joinability of cast aluminium components. </jats:p>}},
  author       = {{Borgert, Thomas and Neuser, Moritz and Wiens, Eugen and Grydin, Olexandr and Homberg, Werner and Schaper, Mirko}},
  booktitle    = {{Materials Research Proceedings}},
  issn         = {{2474-395X}},
  location     = {{Nürnberg}},
  pages        = {{187--194}},
  publisher    = {{Materials Research Forum LLC}},
  title        = {{{Influence of thermo-mechanical joining process on the microstructure of a hypoeutectic aluminium cast alloy}}},
  doi          = {{10.21741/9781644902417-24}},
  volume       = {{25}},
  year         = {{2023}},
}

@article{52405,
  abstract     = {{<jats:p>Multi-material designs (MMD) are more frequently used in the automotive industry. Hereby, the combination of different materials, metal sheets, or cast components, is mechanically joined, often by forming joining processes. The cast components mostly used are high-strength, age-hardenable aluminium alloys of the Al–Si system. Here, the low ductility of the AlSi alloys constitutes a challenge because their brittle nature causes cracks during the joining process. However, by using suitable solidification conditions, it is possible to achieve a microstructure with improved mechanical and joining properties. For this study, we used the twin-roll casting process (TRC) with water-cooled rollers to manufacture the hypoeutectic AlSi10Mg for the first time. Hereby, high solidification rates are realisable, which introduces a microstructure that is about four times finer than in the sand casting process. In particular, it is shown that a fine microstructure close to the modification with Na or Sr is achieved by the high solidification rate in the TRC process without using these elements. Based on this, the mechanical properties increase, and especially the ductility is enhanced. Subsequent joining investigations validate the positive influence of a high solidification rate since cracks in joints can be avoided. Finally, a microstructure-property-joint suitability correlation is presented.</jats:p>}},
  author       = {{Neuser, Moritz and Schaper, Mirko and Grydin, Olexandr}},
  issn         = {{2504-4494}},
  journal      = {{Journal of Manufacturing and Materials Processing}},
  keywords     = {{Industrial and Manufacturing Engineering, Mechanical Engineering, Mechanics of Materials}},
  number       = {{4}},
  publisher    = {{MDPI AG}},
  title        = {{{Mechanical and Microstructure Characterisation of the Hypoeutectic Cast Aluminium Alloy AlSi10Mg Manufactured by the Twin-Roll Casting Process}}},
  doi          = {{10.3390/jmmp7040132}},
  volume       = {{7}},
  year         = {{2023}},
}

@article{47535,
  abstract     = {{<jats:p>Consistent lightweight construction in the area of vehicle manufacturing requires the increased use of multi-material combinations. This, in turn, requires an adaptation of standard joining techniques. In multi-material combinations, the importance of integral cast components, in particular, is increasing and poses additional technical challenges for the industry. One approach to solve these challenges is adaptable joining elements manufactured by a thermomechanical forming process. By applying an incremental and thermomechanical joining process, it is possible to react immediately and adapt the joining process inline to reduce the number of different joining elements. In the investigation described in this publication, cast plates made of the cast aluminium alloy EN AC-AlSi9 serve as joining partners, which are processed by sand casting. The joining process of hypoeutectic AlSi alloys is challenging as their brittle character leads to cracks in the joint during conventional mechanical joining. To solve this, the frictional heat of the novel joining process applied can provide a finer microstructure in the hypoeutectic AlSi9 cast alloy. In detail, its Si is finer-grained, resulting in higher ductility of the joint. This study reveals the thermomechanical joining suitability of a hypoeutectic cast aluminium alloy in combination with adaptively manufactured auxiliary joining elements.</jats:p>}},
  author       = {{Borgert, Thomas and Neuser, Moritz and Hoyer, Kay-Peter and Homberg, Werner and Schaper, Mirko}},
  issn         = {{2504-4494}},
  journal      = {{Journal of Manufacturing and Materials Processing}},
  keywords     = {{Industrial and Manufacturing Engineering, Mechanical Engineering, Mechanics of Materials}},
  number       = {{5}},
  publisher    = {{MDPI AG}},
  title        = {{{Thermomechanical Joining of Hypoeutectic Aluminium Cast Plates}}},
  doi          = {{10.3390/jmmp7050169}},
  volume       = {{7}},
  year         = {{2023}},
}

@inproceedings{52406,
  author       = {{Grydin, Olexandr and Neuser, Moritz and Schaper, Mirko}},
  booktitle    = {{    Conference: ICTP 2023: Proceedings of the 14th International Conference on the Technology of Plasticity - Current Trends in the Technology of PlasticityAt: Cannes (France)}},
  isbn         = {{9783031413407}},
  issn         = {{2195-4356}},
  publisher    = {{Springer Nature Switzerland}},
  title        = {{{Influence of Shell Material on the Microstructure and Mechanical Properties of Twin-Roll Cast Al-Si-Mg Alloy}}},
  doi          = {{10.1007/978-3-031-41341-4_61}},
  year         = {{2023}},
}

@inbook{41959,
  author       = {{Grydin, Olexandr and Garthe, Kai-Uwe and Yuan, Xueyang and Broer, Jette and Keßler, Olaf and Králík, Rostislav and Cieslar, Miroslav and Schaper, Mirko}},
  booktitle    = {{Light Metals 2023}},
  editor       = {{Broek, Stephan}},
  isbn         = {{9783031225314}},
  issn         = {{2367-1181}},
  pages        = {{1031--1037}},
  publisher    = {{Springer Nature Switzerland}},
  title        = {{{Numerical and Experimental Investigation of Twin-Roll Casting of Aluminum–Lithium Strips}}},
  doi          = {{10.1007/978-3-031-22532-1_137}},
  year         = {{2023}},
}

@article{41492,
  abstract     = {{<jats:p>The current investigation shows the feasibility of 316L steel powder production via three different argon gas atomisation routes (closed coupled atomisation, free fall atomisation with and without hot gas), along with subsequent sample production by laser powder bed fusion (PBF-LB). Here, a mixture of pure Fe and atomised 316L steel powder is used for PBF-LB to induce a chemical composition gradient in the microstructure. Optical microscopy and μ-CT investigations proved that the samples processed by PBF-LB exhibit very little porosity. Combined EBSD-EDS measurements show the chemical composition gradient leading to the formation of a local fcc-structure. Upon heat treatment (1100 °C, 14 h), the chemical composition is homogeneous throughout the microstructure. A moderate decrease (1060 to 985 MPa) in the sample’s ultimate tensile strength (UTS) is observed after heat treatment. However, the total elongation of the as-built and heat-treated samples remains the same (≈22%). Similarly, a slight decrease in the hardness from 341 to 307 HV1 is observed upon heat treatment.</jats:p>}},
  author       = {{Pramanik, Sudipta and Andreiev, Anatolii and Hoyer, Kay-Peter and Krüger, Jan Tobias and Hengsbach, Florian and Kircheis, Alexander and Zhao, Weiyu and Fischer-Bühner, Jörg and Schaper, Mirko}},
  issn         = {{2674-0516}},
  journal      = {{Powders}},
  number       = {{1}},
  pages        = {{59--74}},
  publisher    = {{MDPI AG}},
  title        = {{{Powder Production via Atomisation and Subsequent Laser Powder Bed Fusion Processing of Fe+316L Steel Hybrid Alloy}}},
  doi          = {{10.3390/powders2010005}},
  volume       = {{2}},
  year         = {{2023}},
}