Technologies

SIMULATION AND MODELING OF CASTING PROCESSES | An important step for every casting development is the process simulation, in which the design of the casting itself, but also of the mold, is checked for production-compatible design and optimized if necessary. By mapping the entire casting process and subsequent solidification in detail, we can identify areas where casting defects are most likely to occur. The accompanying simulation significantly shortens development times and in many cases enables practical test series to be saved or reduced through realistic mapping of processes and procedures. In the sense of a digital twin, it can also be used for process monitoring and control.

BRINGING NOVEL MATERIALS INTO PRODUCTION! | The field of "Core and Mold Materials" at Fraunhofer IFAM focuses on a wide range of research topics relating to materials and their processes for casting. The demand for higher functional integration in cast components and the associated increase in component complexity on the one hand, and the demand for sustainable, energy-saving processes on the other, is continuously increasing. Both require the development of new core and mold materials and their processes in the world of casting and its products.

TESTING LABORATORY FOR PAINTS, COATINGS AND CORROSION | In the development of paints and coatings as well as the accompanying quality management, standardized suitability tests of the paint are necessary in order to obtain the most accurate characterization of the coating system. Fraunhofer IFAM offers a wide range of test methods to determine and verify adhesion, elasticity, hardness, chemical resistance, and weather resistance. Paint testing is carried out both on liquid paints and on cured coatings. Depending on the application, these are subjected to varying loads – under laboratory conditions or in outdoor weathering. For this purpose, the researchers use standardized test procedures, but also develop customized test and testing methods if required.

DETERMINATION OF REACTION ENTHALPIES OF MOISTURE-SENSITIVE MATERIALS UNDER INERT GAS ATMOSPHERE | The enthalpy measurement of mixing reactions during the synthesis of air-sensitive materials must be carried out under inert conditions and thus places special demands on the measurement setup. One example of moisture-sensitive materials are sulfide solid-state electrolytes, which may be used in future solid-state batteries (ASSBs). To make these materials economically attractive, Fraunhofer IFAM is researching the scale-up of the synthesis process. For the upscaling of the syntheses, reaction enthalpies are required, which must be measured in an inert gas atmosphere.

We cover the complete value chain for the additive processes we have available at Fraunhofer IFAM – from the creation of 3D data models, through manufacturing, to final processing and inspection of the components.

VUV RADIATION OPTIMIZES SILICONE PROPERTIES AT THE SURFACE | We encounter silicone elastomers in many different areas. Due to their high elasticity, very good temperature resistance and biocompatibility, they are suitable for a wide variety of applications, for example in medical or food technology. The surface properties of the material, on the other hand, are not ideal and make it difficult to use in certain applications. For example, silicones are susceptible to wear, attract dirt, and can only be bonded to a limited extent. At Fraunhofer IFAM, a process has been developed which allows the surfaces to be modified quickly and flexibly without impairing the excellent mechanical properties of the silicones.

LASER TECHNOLOGY ENABLED STABLE INTERFACES FOR METAL HYBRID CASTING AND PLASTIC INJECTION MOLDING TO INCREASE COMPOSITE STRENGTH | Laser technology offers optimal possibilities for the pre-treatment of surfaces. Researchers at Fraunhofer IFAM have succeeded in achieving a significant increase in composite strength in metal-metal, metal-plastic or plastic composites by means of laser pre-treatment. The high interfacial strengths result from positive and non-positive micro-interlocking between the laser-treated component and the infiltrated metal or plastic. Innovative laser-induced channels on components, which enable complete infiltration with melts or plastics, are fundamental. In addition, production time and costs can be saved compared to conventional joining methods by integrating the joining process into the primary forming process.

Corrosion protection plays an important role in many industries such as medical technology or plant engineering. If, for example, sensitive optics or medical equipment are to be protected against corrosion and abrasion, or if aluminum die-cast housings are to be sealed for long-term durability, transparent plasma coatings are the right choice.

PLASMA COATINGS: CHEMICAL-FREE THIN FILMS FOR NEW SURFACE AND PRODUCT PROPERTIES | The demand for special functional coatings for products and semi-finished products is very high in many industrial sectors - from automotive production and plastics processing to medical technology or biotechnology. Fraunhofer IFAM is researching and developing plasma-assisted coating processes which decisively improve the range of properties of these (semi-finished) products almost independently of the material used. And without the use of chemicals! This makes these processes particularly interesting at present, because it helps companies to comply with regulations such as the REACH regulation or the HSE guidelines.

SOLVER BASED SIMULATION ENVIRONMENT FOR TECHNO-ECONOMIC POTENTIAL ANALYSIS OF VARIOUS ENERGY SYSTEMS | The energy system of the future will have to master many different challenges. At Fraunhofer IFAM, a wide variety of energy systems can be observed and analyzed using a simulation environment developed in-house, with the focus on buildings and the topic of electromobility. The simulation environment has been developed in a way that it can be adapted to a wide range of requirements and needs. Individual assumptions about possible future developments can also be taken into account in the simulation and optimization calculations.