The detailed analysis and reliable design of thermo-mechanically highly loaded structures requires a physically well-founded description of the underlying material behaviour. Material models are primarily used in analysis and design by means of nonlinear finite element methods (FEM). Examples range from steam turbines, sealing and damping elements to additively manufactured, metallic components. Particularly in the context of the energy transition, consistent lightweight construction and the realisation of a circular economy, the characterisation and description of the mechanical behaviour of new materials is of special importance.

Our expertise includes the mechanical, thermo-mechanical and thermo-physical characterisation and modelling of polymers and metals. The material models used describe linear and non-linear elasticity, viscoelasticity, plasticity and viscoplasticity as well as fatigue (LCF, HCF) and creep damage for lifetime prediction. Temperature and rate dependencies are also taken into account. Thermo-physical parameters include density, thermal conduction as well as thermal expansion.

Additive manufacturing of metallic components enables the production of complex and highly integrated lightweight and functional parts. At the same time, it has great potential to disrupt the existing manufacturing landscape with its high degree of flexibility and sustainability. However, the great complexity of this promising manufacturing technology requires a great deal of know-how in order to realise the necessary reliability and economic efficiency.

Thermo-mechanical process simulation can help in the design and production preparation of additively manufactured components to improve the reliability and economic efficiency of this promising process. Our expertise lies in the simulation of process-related thermo-mechanical distortion. For this purpose, both simplified inherent strain and advanced thermo-mechanical approaches are pursued. To ensure reliable predictions, we use a comprehensive basic thermo-physical characterisation of the additively processed materials. We are also specialised in the component-like calibration of all leading process simulation solutions. In this way, we ensure reliable predictions of stresses and distortions. On this basis, build strategies, support structures and additively manufactured components can be optimised and distortion compensated for in advance.