Compensation Methods


Head of the Working Group

Dr.-Ing. Arnold Gillner
Chair of Laser Technology LLT

The “Compensation Methods” working group is concerned with control of the melt flow, the process-dependent modulation of the heat flow and, in this way, the targeted manipulation of the solidification process. Furthermore, the group discusses mechanisms to compensate for possible inaccuracies such as distortion, warpage, cavities, surface inaccuracies, and other quality-reducing effects in melt-based manufacturing processes. In this way, the group seeks to reduce error rates and improve accuracy in manufacturing.


Working Groups

Thermal imaging Thermal imaging

Process Regulation and In-Situ Process Parameter Determination

The Process Regulation and In-Situ Process Parameter Determination working group deals with the possibilities of intervention in certain melting processes in order to carry out a process regulation or control through in-situ parameter determination.

As a result, mistakes, such as resulting delays or internal stress, can be monitored based on determinable input sizes and combined and with an online process regulation.

In this working group, the characteristic melting and solidification dynamics for the respective process are evaluated and the responsiveness (controllability) of the process and melting is discussed. The goal of this exchange is a joint deduction of melting parameters and the possibilities to guide them via external process actuators.

Active members: A2 , A7 , A8 , A9 , A10 , A11 , B3
Informing members: B4

  Microscope image of a lot Microscope image of a lot

Material Influence / Microstructure Composition

The Material Influence/Microstructure Composition working group is active at multiple levels dealing with the adjustment of desired microstructure and phase formation in the solidified molten mass. Using additional material to influence the viscosity and composition of the molten mass, the flow and solidification behavior are shaped. Thermodynamic and thermomechanical characteristics of the molten mass are influenced by suitable temperature control and diffusion processes after solidification are a focus that should be controlled through suitable process direction. This involves both metallic molten masses and plastic molten masses.

Active members: A1, A3, A4, A5, A6, A7, A10, A11, B4, B7, B8
Informing members: B1, B3, A9

  CAD representation of a casting system CAD representation of a casting system

Thermal Influence in Process Control

The Thermal Influence in Process Control working group focuses on the targeted, thermal management of the molten mass during the process. Targeted energy insertion and deduction are used and the resulting effects, such as shrinking, warpage, overheating the mass with emissions, and the molding accuracies needed for the casting process are taken into consideration. They are compensated for through an adapted temperature profile of the molten mass. Collaboration takes place in the strategies for energy insertion, the consideration of the effects of local temperature control, and the control of local temperature gradients with corresponding, modified energy dispersion.

Active members: A1, A3, A5, A7, A8, A9, A11, B1, B3, B6
Informing members: B4

  FEM model of complex component during cooling down process FEM model of complex component during cooling down process

Compensation for Complex Geometries

The Compensation for Complex Geometries working groups works on compensation methods for complex joint layout and complex geometries in casting applications, in which the flow of energy is destroyed by the component geometry. As a result, energy input and dissipation can lead to component defects in process controls that have not been adapted. Technological marginal conditions for components and geometries relevant to production are evaluated across all processes and the developed compensation methods are adapted. There is an active exchange with the working group Thermal Influence in Process Control. Furthermore, enhanced approaches for compensating for process mistakes are taken into consideration when designing workpieces adapted to energy and molten mass.

Active members: A5, A7, B1, B2, B3, B5, B6, B8, B9
Informing members: B7