Fabian Esterl, M.Sc.

21335 Lüneburg, Universitätsallee 1, C12.220
Fon +49.4131.677-1951, fabian.esterl@leuphana.de
Wiss. Mitarbeiter*in, Professorship of Manufacturing – Innovative Manufacturing
Promovierende*r, Professorship of Manufacturing – Innovative Manufacturing

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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

Publications

Journal contributions

  1. From billet to extruded band: Engineering texture and properties in AA6082 through die design and billet condition
    Maria Nienaber (Author) , Fabian Thomas Esterl (Author) , Noomane Ben Khalifa (Author) , Jan Bohlen (Author) , 01.02.2026 , in: Materials and Design, 262

    Research output: Journal contributions › Journal articles › Research › peer-review

  2. Analysis of tailored residual stress fields of deep rolled AA2024 sheets
    Jonas Lehmann (Author) , Dominik Pöltl (Author) , Fabian Thomas Esterl (Author) , Nikolai Kashaev (Author) , Noomane Ben Khalifa (Author) , 01.09.2025 , in: International Journal of Material Forming, 18, 3 , 12 p.

    Research output: Journal contributions › Journal articles › Research › peer-review

  3. Connecting texture development to die design in extruded flat products
    Fabian Thomas Esterl (Author) , Noomane Ben Khalifa (Author) , Maria Nienaber (Author) , Jan Bohlen (Author) , 31.01.2025 , in: Journal of Manufacturing Processes, 134 , p. 891-903 , 13 p.

    Research output: Journal contributions › Journal articles › Research › peer-review

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Contributions to collected editions/anthologies

  1. Deep Rolling for Tailoring Residual Stresses of AA2024 Sheet Metals
    Jonas Lehmann (Author) , Sören Keller (Author) , Fabian Thomas Esterl (Author) , Benjamin Klusemann (Author) , Noomane Ben Khalifa (Author) , Nikolai Kashaev (Author) , 01.01.2024 Cham , p. 352-362 , 11 p.

    Research output: Contributions to collected editions/anthologies › Article in conference proceedings › Research › peer-review

  2. Reduction of Anisotropic Mechanical Properties During Extrusion by Means of Additively Manufactured Dies
    Fabian Thomas Esterl (Author) , Noomane Ben Khalifa (Author) , Maria Nienaber (Author) , Jan Bohlen (Author) , 01.01.2024 Kyoto , p. 29-30 , 2 p.

    Research output: Contributions to collected editions/anthologies › Published abstract in conference proceedings › Research

  3. Development of a Parameterized Model for Additively Manufactured Dies to Control the Strains in Extrudates
    Fabian Thomas Esterl (Author) , Noomane Ben Khalifa (Author) , Maria Nienaber (Author) , Jan Bohlen (Author) , 01.01.2024 , p. 1-8 , 8 p.

    Research output: Contributions to collected editions/anthologies › Article in conference proceedings › Research › peer-review

  4. Flow Behavior Investigation during Miniaturized Extrusion of Aluminum (AA6082) and Magnesium (AZ31)
    Fabian Thomas Esterl (Author) , Jonas Lehmann (Author) , Noomane Ben Khalifa (Author) , Maria Nienaber (Author) , Jan Bohlen (Author) , 01.01.2024 , p. 1-7 , 7 p.

    Research output: Contributions to collected editions/anthologies › Article in conference proceedings › Research › peer-review

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Courses