Innovative Product Development by Additive Manufacturing 27. September 2022

In additive manufacturing, differential design is becoming increasingly important as a complementary design method to integral design. Consequently, the need for component connections increases. In preliminary investigations, electrochemical metal deposition has been shown to be promising as a joining method. In this publication, the process preparation steps are improved. Subsequently, the influence of geometry parameters on the material distribution in the joining zone is considered using specimen made of AlSi10Mg. For this purpose, characterizing features of the finished joint are identified and the effect of geometry on these features is investigated. In addition, a brief comparison of the effect of geometry on the tensile strength of a purely material bonded joint is drawn. An opposite behavior between improved tensile strength and reduction of material agglomeration is found. Finally, suggestions are given for improving the joint by modifying part design and process based on the current state of research.