Magazine

ALTERNATIVE MAGNETS FOR ELECTRIC DRIVES | The conservation of raw materials is becoming an crucial aspect of the development of electric machines. For instance, rare earth elements are employed the production of magnets for synchronous machines. However, these elements are not only expensive but also in limited supply, which is why they are mostly imported from China. As a result, electric machine manufacturers are actively seeking alternatives. At Fraunhofer IFAM, research is being conducted on materials that are not only more cost-effective but also reduce dependence on rare earth elements. This is of great interest to the industry, given the extreme price fluctuations and China's dominance in rare earth mining.

Our environment is under increasing pressure from chemical pollutants contaminating soil, water, and air. Particularly concerning are persistent substances such as per- and polyfluoroalkyl substances (PFAS) and pharmaceutical residues. These belong to a group of over 4,700 compounds whose effects on human health and ecosystems remain largely unknown. Despite advanced wastewater treatment technologies, any of these pollutants still enter the environment, threatening fragile ecosystems – even in remote regions like the Arctic. This is where the R&D project DeDrug-Bio comes in. By leveraging biohybrid filtration systems, harmful substances can be removed efficiently and sustainably – an innovative approach that seamlessly integrates nature and technology.

COMMON CHALLENGES FOR ENERGY SUPPLIERS, COMMUNES AND THE HOUSING INDUSTRY | The sustainability goals at federal and state level in Germany require a climate-friendly heat supply. The goal of a climate-neutral building stock by 2045 can only be achieved through an innovative and sustainable heat supply. Therefore, energy suppliers and communes as well as the housing industry must face common challenges and work together in order to master them. Fraunhofer IFAM provides support with strategic planning of the heat supply and takes into account the various possible supply options and their economic efficiency.

PROJECT “BioRUHM”: REACTIVE URETHANE-FREE HOTMELT ADHESIVE | Reactive hot-melt adhesives (RHM) based on isocyanate are increasingly being used due to their exceptional properties, from packaging to automotive construction and technical textiles. However, the composition of these urethane-based adhesives also involves risks, e.g. the release of hazardous isocyanate. In the “BioRUHM” project, Fraunhofer IFAM is working with project partners to develop a urethane-free concept.

METHODS FOR APPLYING SEALANT TO BIPOLAR PLATES USING SCREEN PRINTING | Fraunhofer IFAM is your competent partner for innovative research services in the field of fuel cell production. In addition to industrial projects in this context, we are active in public research projects - including the National Action Plan for Fuel Cell Production (H2GO). The National Action Plan maps the key sensitivities of the value chain in the production, stacking and recycling of substantial fuel cell components. Fraunhofer IFAM is, among other things, researching the use of the screen printing process for applying sealants to bipolar plates, which has several other advantages in addition to reducing production costs.

SALT SPRAY, CROSS-CUT AND G1C TESTING ACCORDING TO NADCAP | Since March 2020, parts of the laboratories at the Bremen site have been recognized under the Nadcap conformity system relevant to the aviation industry. The successfully obtained Nadcap "accreditation" as an independent testing laboratory in the field of chemical processing applies, among other things, to the cross-cut test according to DIN EN ISO 2409 and the salt spray test according to DIN EN ISO 9227, which are important for coatings. In the field of Non-Metallic Materials Testing (NMMT) recognition has been valid since June 2021 for the testing of composite materials (CFRP) according to AITM 1-0053 (G1c procedure).

DEVELOPMENT OF ROTORS FOR EFFICIENT INDUCTION MACHINES (IM) | Fraunhofer IFAM is developing solutions for more economical and efficient Induction machine (IM). IMs are still widely used in electrical drive applications, particularly in the field of industrial drives. They are robust and cost-effective and can start up directly from the line without a frequency converter if required. Even in vehicle technology, IMs are certainly far from being replaced . New manufacturing approaches continue to offer potential for increasing efficiency, reducing costs and improving production quality.

MULTIDISCIPLINARY DESIGN AUTOMATION AS A SOLUTION TO CURRENT CHALLENGES | As electrification progresses and the use of inverter-fed electric motors increases, manufacturers and developers face new challenges. Ever-shorter development cycles, coupled with constantly rising demands for efficiency or torque density, require innovative approaches in the multidomain development of electric machines. A promising solution lies in the creation of integrated simulation-driven design workflows that enable the automated generation and evaluation of various designs. At Fraunhofer IFAM, specific methods and demand-driven design workflows are being developed to quickly create designs for electric machines and evaluate them in light of manufacturing and materials science innovations.

In the project "UltraHybRo", the experts of the area "Electric Drive Technology" at Fraunhofer Ifam are developing a joining process for the manufacture of squirrel cage rotors for induction machines together with the project partner mth Ultraschalltechnologie GmbH & Co. KG. They are pursuing a novel approach to increase the efficiency of induction machines over a wide operating range.

CAST COILS FOR HIGH-PERFORMANCE ELECTRIC MOTORS | The advancement of electrification represents a central future topic for the industry. Technological progress in the field of electric drives has not only led to broader acceptance of this technology but also to increased demand for more efficient and powerful drive systems. In this context, cast coils made of aluminum and copper have been developed at Fraunhofer IFAM. The casting production of coils not only enables electric motors with higher power density but also allows for more cost-effective, efficient, and lightweight designs.