Fabian Esterl, M.Sc.
Vita
since 10.2025 Chief Engineer - Professorship of Manufacturing (IPTS)
since 07.2023 Research associate - Professorship of Manufacturing (IPTS)
10.2021 to 07.2023 Master of Science "Management & Engineering", Leuphana University of Lüneburg
08.2019 to 07.2023 Student assistant at the IPTS
10.2018 to 09.2021 Bachelor of Engineering "Engineering", Leuphana University of Lüneburg
Research Interests
My research deals with the emergence and influencing of the anisotropic mechanical behavior of metallic profiles by extrusion. Anisotropy during extrusion is always detectable for various materials, especially aluminum, and magnesium, but can differ in quantity depending on the alloy and geometry. A new approach is being pursued to control the material flow in the extrusion die in such a way that the anisotropy of the mechanical properties is specifically and measurably influenced and reduced. The possibility of controlling the material flow is realized via a novel design and manufacturing of extrusion dies incorporating additive manufacturing technology. The mechanical properties of the materials are specifically influenced by the directed material flow and the associated microstructure development. At the crystallographic level, the deformation acting on the material produces a pronounced texture, which causes the anisotropic mechanical behavior of the profile through the directional dependence of activated deformation mechanisms. The specific adaptation of the material flow in the die and the resulting change in the stress and strain state in the forming process can be described and controlled in this way. This allows the design guidelines for the required microstructure development to be designated for the targeted reduction of the anisotropic mechanical behavior of the extruded profiles.
The project is funded by the DFG (German Research Foundation).
Projects
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Reduction of anisotropic material properties during extrusion through additively manufactured extrusion dies
Noomane Ben Khalifa (Project manager, academic) , Jan Bohlen (Project manager, academic) , Fabian Esterl (Project staff) , Jonas Lehmann (Project staff)
→Project: Research
Publications
Journal contributions
- Mechanical performance during corrosion of magnesium alloy wires in artificial urine solution: Insights from an alloy study
Maria Nienaber (Author) , Mengyao Liu (Author) , Margarida Pacheco (Author) , Fabian Esterl (Author) , Merle Braatz (Author) , Alexandre Barros (Author) , Rui L. Reis (Author) , Mikhail L Zheludkevich (Author) , Noomane Ben Khalifa (Author) , Sviatlana V. Lamaka (Author) , Jan Bohlen (Author) , 01.04.2026 , in: Materials Science and Engineering: A, 957 , 12 p.Research output: Journal contributions › Journal articles › Research › peer-review
- From billet to extruded band: Engineering texture and properties in AA6082 through die design and billet condition
Maria Nienaber (Author) , Fabian Esterl (Author) , Noomane Ben Khalifa (Author) , Jan Bohlen (Author) , 01.02.2026 , in: Materials and Design, 262 , 16 p.Research output: Journal contributions › Journal articles › Research › peer-review
- Analysis of tailored residual stress fields of deep rolled AA2024 sheets
Fabian Esterl (Author) , Nikolai Kashaev (Author) , Noomane Ben Khalifa (Author) , Jonas Lehmann (Author) , Dominik Pöltl (Author) , 01.09.2025 , in: International Journal of Material Forming, 18, 3 , 12 p.Research output: Journal contributions › Journal articles › Research › peer-review
- Connecting texture development to die design in extruded flat products
Fabian Esterl (Author) , Maria Nienaber (Author) , Jan Bohlen (Author) , Noomane Ben Khalifa (Author) , 31.01.2025 , in: Journal of Manufacturing Processes, 134 , p. 891-903 , 13 p.Research output: Journal contributions › Journal articles › Research › peer-review
Contributions to collected editions/anthologies
- Deep Rolling for Tailoring Residual Stresses of AA2024 Sheet Metals
Fabian Esterl (Author) , Nikolai Kashaev (Author) , Benjamin Klusemann (Author) , Noomane Ben Khalifa (Author) , Jonas Lehmann (Author) , Sören Keller (Author) , 01.01.2024 Cham , p. 352-362 , 11 p.Research output: Contributions to collected editions/anthologies › Article in conference proceedings › Research › peer-review
- Reduction of Anisotropic Mechanical Properties During Extrusion by Means of Additively Manufactured Dies
Fabian Esterl (Author) , Maria Nienaber (Author) , Jan Bohlen (Author) , Noomane Ben Khalifa (Author) , 01.01.2024 Kyoto , p. 29-30 , 2 p.Research output: Contributions to collected editions/anthologies › Published abstract in conference proceedings › Research
- Development of a Parameterized Model for Additively Manufactured Dies to Control the Strains in Extrudates
Fabian Esterl (Author) , Maria Nienaber (Author) , Jan Bohlen (Author) , Noomane Ben Khalifa (Author) , 01.01.2024 , p. 1-8 , 8 p.Research output: Contributions to collected editions/anthologies › Article in conference proceedings › Research › peer-review
- Flow Behavior Investigation during Miniaturized Extrusion of Aluminum (AA6082) and Magnesium (AZ31)
Maria Nienaber (Author) , Fabian Esterl (Author) , Jan Bohlen (Author) , Noomane Ben Khalifa (Author) , Jonas Lehmann (Author) , 01.01.2024 , p. 1-7 , 7 p.Research output: Contributions to collected editions/anthologies › Article in conference proceedings › Research › peer-review
Courses
In der Lehrveranstaltung werden von den Studierenden in Kleingruppen Lampen aus recycelten Materialen gefertigt. Nach einer Einführung in das Thema wird altes Material beschafft und ein Konzept für einen Lampenschirm entwickelt. Die Bleche werden anhand von Zugversuchen charakterisiert. Die Lampenschirme sollen aus dem Blechmaterial inkrementell umgeformt werden. Der letzte Schritt ist die Montage der Einzelteile zu einer Tisch-Stehlampe. Für die schriftliche Hausarbeit soll eine überschlägige Energiebilanz zur Bewertung der Nachhaltigkeit erstellt werden.