Process Fundamentals

A fundamental understanding of the physical mechanisms underlying modern manufacturing processes is essential for developing production technologies that are reproducible, scalable and scientifically controllable. Within the Process Fundamentals research area, we investigate the interactions between energy input, material state and process dynamics with the aim of quantitatively describing the underlying mechanisms of manufacturing processes and making them systematically accessible for targeted process design.

We study thermal, fluid-dynamic, metallurgical and chemical phenomena across different length and time scales. A central focus lies on the coupling between process control, transient process states and the resulting material and component properties. Our goal is to establish robust relationships between process inputs, local process states and the functional performance of manufactured components.

A particular focus is on Laser Powder Bed Fusion of Metals (PBF-LB/M). Here, we investigate the physical mechanisms of laser–material interaction during localized energy input. These include, in particular, energy absorption, heat and mass transfer, melt pool and keyhole dynamics, evaporation phenomena, as well as the formation of temperature, flow and concentration fields.

These processes govern local microstructure evolution, defect formation, residual stresses and the resulting mechanical and functional properties of additively manufactured components. Our research aims to make these relationships experimentally and model-based accessible and to derive robust approaches for process understanding, process control and material design.

To achieve this, we combine high-resolution experimental methods with numerical modeling, as well as dedicated research platforms and test rigs developed in-house. These enable targeted interventions in individual physical mechanisms and the controlled variation of relevant boundary conditions.