Joining Technology and Additive Manufacturing

- Tasks / Main focus
- Special facilities
- Contact person

Department 57 Joining Technology and Additive Manufacturing is subdivided into the following Units:

  • Unit 571  Additive Manufacturing
  • Unit 572  Joining Technology
  • Unit 573  Stress Analysis and Residual Stress

The department Joining Technology and Additive Manufacturing considers both joining technologies and additive manufacturing as a system of process technology, material condition and resulting strength properties.
The influence of process parameters on emerging microstructure, formation of geometry and finally the mechanical properties is investigated in experimental studies and numerical process simulations.
A well-equipped laboratory is available for experimental studies of manufacturing and processing problems. Besides experimental investigations of process limits and determination of stable parameters for existing joining processes, we develop new and derived processes; especially for joining of different materials.
Continuum mechanical simulation models are developed for several welding processes. These models include complex material behavior as for example temperature and strain rate dependent solidification through individual material models. Furthermore a specially implemented sequential linking approach takes into account the thermal-mechanical-electrical interaction which occurs for example in resistance spot welding.
Normally, high temperature gradients occur in joining processes and additive manufacturing; this can result in complex residual stresses. Residual stresses superimpose operating stresses and therefore often significantly reduce the vibration resistance of joints and additively manufactured components.
Residual stresses of weld joints and large parts as well as operation stresses of large parts and components are measured through experimental stress analysis.

Messung von lokalen Verformungen in gekerbten Proben
MPA staff performing residual stress measurements on site
Tasks / Main focus
  • Continuum mechanical simulation of resistance spot welding
  • Modelling of friction stir welding
  • Numerical simulation methods for additive manufacturing
  • Optimization of the friction stir welding process of aluminum-steel connections
  • Development of methods for selecting joining processes in multi-material lightweight constructions
  • Interaction between joining technologies and thermal treatment
  • Examination and evaluation of additively manufactured specimens and components
  • Development of new joining configurations for hybrid material connections
  • Development of material models for simulating welding processes
  • Development of new processes to determine residual stresses
  • Development of force transducers for special operating conditions
Haerte - Vergleich Schliff - Simulation
Comparison of numerical (top) and experimental (bottom) determined hardness according to Vickers (HV0.1) of a resistance spot welding
Comparison of nugget, heat affected zone (above Ac1-temperature) and softened zone (below Ac1-temperature) from numerical calculation and experiment for sample MB003
Investigations / Analyses / Expertises
  • Conduct of sample welds
  • Consulting in joining technology
  • On-site support, reconstruction of welding problems in the laboratory and failure analysis
  • Measurement of process variables like power, voltage, force, displacement, temperature, …
  • Determination of contact resistance and electrical material resistance
  • Quantification of residual stresses
  • Application of strain gauges and redesign of components for force measuring
  • Optical strain measurement
  • Physical simulation of characteristic structure formation during welding
Screw with strain gauges for measurement of forces
Cooperation in Committees
  • DVS technical committee 5 special welding methods
  • DVS technical committee 4 resistance welding
  • DVS working group V11.2 friction stir welding
  • DVS working group V3.2 spot welding, projection welding and seam welding
  • Employees of the department are responsible for the lecture in joining technology and contribute to other lectures as well
  • Employees of the department are responsible for the lecture in joining technology and contribute to other lectures as well
  • Supervision of master theses in industrial companies is also possible by agreement respectively in cooperation with the IMWF
Bohrloch Experimenteller Vergleich
Combination of the hole drilling and separation method on an inner measuring position
Experimental comparison of different methods for measuring residual stresses
Special facilities
  • Friction stir welding machine
  • Resistance welding plant for spot and projection welding
  • Ultra-sonic welding plant
  • Gleeble (testing machine for thermo-mechanical physical structure simulation)
  • Various universal testing machines e.g. for tensile, pressure and bending tests
Further Information
Contact person


Mrs. A. Zenk

++49 (0)711/685-60724

Head of Department

Mr. Dipl.-Ing. M. Werz


++49 (0)711/685-62597
++49 (0)711/685-63053

Mr. Dipl.-Ing. F. Schreyer

++49 (0)711/685-63033
++49 (0)711/685-63053


Additive Manufacturing

Mr. Dipl.-Ing. M. Werz


++49 (0)711/685-62597

Joining Technology

Mr. Dipl.-Ing. F. Schreyer

++49 (0)711/685-63033

Stress Analysis and Residual

Mr. Dipl.-Ing. A. Schlüter

++49 (0)711/685-62593