Press releases

At the JEC World Composite Show in Paris this March, the Fraunhofer Institute for Structural Durability and System Reliability LBF in Darmstadt and the Fraunhofer Institute for Laser Technology ILT in Aachen will be demonstrating how well-coordinated collaboration makes it possible to optimize a hybrid automotive component for series production: Together with their industrial partners, these Fraunhofer institutes have developed a multi-material roof bow as an exhibition piece, which the researchers are looking to present for the first time at a joint booth hosted by the Aachen Center for Integrative Lightweight Production AZL, Hall 5/C55.

The ability to test various materials without destroying them is essential in many areas of commerce and industry. The Fraunhofer Institute for Structural Durability and System Reliability LBF has now developed a new method that for the first time combines the mechanical testing of a component under realistic loads with a radiographic examination. The method is used to characterize materials, and it makes it easier to assess inclusions or damage to raw material with regard to their influence on the durability and service life. In so doing, Fraunhofer LBF provides materials designers and manufacturers as well as scientists with information for better understanding of material behavior and material characterization.

In the past, service life tests for vehicles or individual components required test drives on the road lasting several days. Today, thanks to cutting-edge testing facilities, a few hours in the laboratory is enough. The Fraunhofer Institute for Structural Durability and System Reliability LBF has specialized in recent years in the area of wheel testing and approval. Thanks to its diverse development and testing activities the institute has carved out a position for itself as a technology leader. The UC 13 – Users Conference on Biaxial Fatigue Testing for Wheels and Wheel Hubs held on November 8 in Darmstadt provided an opportunity to find out more about the latest developments in this area of technology and to swap experiences. Around 50 scientists and users from Europe, Asia and the USA gathered in Fraunhofer LBF for the conference, the 13th to be held.

Functionalized polyolefins are of great economic importance as bonding agents between polyolefins and polar surfaces. Despite years of effort, up to now there has never been any analytic method that could provide a comprehensive understanding of these materials to enable their effectiveness to be quickly assessed, for instance as part of incoming goods controlling. Now, a chromatographic method developed at the Fraunhofer Institute for Structural Durability and System Reliability LBF makes it possible to develop systematic structure-property relationships for these materials for the first time. This is very useful for the development of more efficient functionalization processes. In addition, this analytic information is highly relevant for material development and for understanding material failure.

The durability of materials, components or constructions is sometimes reduced greatly due to complex load conditions. These effects must be taken into consideration, particularly for safety components. Furthermore, products have to be produced in an easy, cost-effective, efficient manner – diametrically opposed challenges. At the International Symposium on Structural Durability in Darmstadt, Germany, on May 17-18, 2017, experts will discuss complex load situations and how they can be assessed realistically. For more information, see www.sosdid.de

Diesel engines vibrate. This produces tremendous stress on the components of ships. Adaptronic systems effectively reduce these vibrations. At the maritime trade fair SMM, Fraunhofer researchers are presenting a simulation tool that allows these systems to be developed efficiently: The “Mechanical Simulation Toolbox“ is now available on the market and easy to use.

Zero plastics to landfill increases the need to mechanical recycling of plastics. This also applies to flame retardant plastics which are increasingly formulated with halogen-free flame retardants. The use of flame retardants can prevent the fire spreading or slow its development. According to EU regulations, plastic waste recycling is to increase in quality, and recycling rates should continue to rise: the EU target for 2020 is 70 percent. So it is all the more important for economically viable recycling to conduct the necessary basic studies in good time. The Fraunhofer Institute for Structural Durability and System Reliability LBF has therefore launched a new research project on the recycling of halogen-free flame retardant plastics. For the first time, the project will provide answers to the recyclability of halogen-free flame retardant plastics. Small and medium-sized companies in particular should be able to reduce costs in this highly market-relevant area and produce enhanced quality products with high safety standards.

When plastics are developed, it’s okay to “go a bit over the edge”. Because to be able to make reliable statements on the application options for new polymers, excipients, and additives, it is important to be able to process them into components and test specimens, as well as characterize and test them under realistic conditions. However, this requires them to be available in sufficient quantities. For this reason, the Fraunhofer Institute for Structural Durability and System Reliability LBF, based on many years of experience in polymer research, has set up a new kilogram lab that enables laboratory syntheses to be upscaled to kilograms. In reactors and autoclaves with a volume of up to 20 liters, the scientists are capable of carrying out polymerizations and organic syntheses under different conditions. The products obtained can then be examined practically.

When polymers are used in new areas of application or different materials are combined in an innovative way, it is the interfaces and their design that really matter. Block copolymers have proven to be a very versatile tool for this purpose and they are currently being developed by the Plastics Division of the Fraunhofer Institute for Structural Durability and System Reliability LBF. With the appropriate design, the block copolymers adsorb in the interface, thereby improving the property profile of the multiphase polymer systems. The Institute matches the blocks of the copolymers to the materials that need to be combined and designs customized solutions for a variety of different polymers. These include, for example, polyolefins or polycondensates in which the synthesis of block copolymers is very demanding. It is also possible to integrate suitable functional anchor groups in the compatibilizer for attaching polymers to surfaces of different classes of materials, such as inorganic and organic fillers and fibers, as well as glass, ceramic or metal surfaces. With block copolymers as adhesion and phase compatibilizers, the Fraunhofer LBF can improve the mechanical, physical or optical properties of various materials. For example, the Institute is currently optimizing thermoplastic elastomers, impact modification of brittle polymers, and also adhesion between polymers and materials of other classes.