Business Unit Aviation

The aviation industry is currently facing a number of challenges that have both short-term and long-term effects. One key issue is the sustainable development and reduction of CO2 emissions. Airlines and manufacturers are challenged to develop and implement innovative technologies such as alternative fuels and more efficient aircraft designs. The pandemic has shown how vulnerable the industry is to global crises. Flexible business models and comprehensive crisis management strategies are therefore essential in order to better meet future challenges.

Together with research partners, Fraunhofer IFAM is developing integrated overall concepts to strengthen the industrial competitiveness of the aviation industry, taking into account the requirements of environmental protection and sustainability. This takes place in bilateral, regional, national and European projects with the Fraunhofer IFAM focus on materials, processes and production.

The following publicly funded projects illustrate the diversity of Fraunhofer IFAM's activities in the aviation sector. These are based on our expertise in metallic and polymeric materials and their surfaces. Processes and production methods are also a key focus.

Exceptional competencies are particularly evident in the nationally funded project Bellissima, as well as in the UP Wing and MFFD projects, which are conducted under the EU programs Clean Aviation and Clean Sky.

The publicly funded projects presented below illustrate the range of Fraunhofer IFAM activities in the field of aerospace, which are based on a deep understanding of metallic and polymer materials and their surfaces. The focus here is also on processes and production methods. These special competencies are particularly evident in the funded Bellissima project and the UP Wing and MFFD projects as part of the EU Clean Aviation and Clean Sky programs.

 

Efficient laser paint stripping, surface preparation and precise painting for aircraft structures

As part of the German Federal Government's Aviation Research Program VI (LuFo VI), the Bellissima project was launched. The aim of the project is to investigate and improve the processes for removing old paint layers, surface preparation, and precise repainting of aircraft. These techniques are also applicable to initial painting, where surface preparation plays a crucial role.

The optimized procedures significantly reduce overspray. At the same time, many time-consuming steps, such as masking, as well as the use of cleaning agents and masking materials, can be avoided. This not only saves time but also valuable resources.

 

Ultra Performance Wing as part of the EU Clean Aviation program

In the current European aviation program Clean Aviation, which has a budget of €4.1 billion, the results from the predecessor program Clean Sky 2 are being adopted and developed further. The goal is to lead European aviation towards the reduction of CO2 emissions by 2050 through innovative technologies and to strengthen the collaboration of all partners.

The program focuses on three main themes:

• Hydrogen-powered aircraft
• Ultra-efficient aircraft for short and medium distances
• Hybrid-electric regional aircraft

Fraunhofer, as a founding member of the program, is involved in various sub-projects. The sub-project Ultra Performance Wing, in which Fraunhofer IFAM participates, focuses on innovative approaches and technologies for the aerodynamics and manufacturing of wings for short and medium-distance aircraft. IFAM's contribution includes, among other things, the investigation of anti-erosion coatings for the leading edge of wings and automatable pre-treatment processes.

The Ultra Performance Wing project (UP Wing, project number: 101101974) is funded by the “Clean Aviation Joint Undertaking” and its members.

 

MultiFunctional Fuselage Demonstrator as part of the EU Clean Aviation program

In the MFFD project, we are developing a new, highly integrated approach to the design and manufacture of aircraft fuselages. The aim is to reduce structural weight, increase manufacturing efficiency and improve repair and recycling options.

As part of the project, Fraunhofer IFAM is making significant contributions to the joining technology of large structures, which are being tested on the full-scale demonstrator. This demonstrator is a highly automated and flexible production system that is being comprehensively validated in the MFFD project.

The Multifunctional Fuselage Demonstrator (MFFD) project is part of the Large Passenger Aircraft Program (LPA, project number 945583) and is funded by the “Clean Sky Joint Undertaking” and its members.