Press releases

Design of plastic components is primarily based on the methods developed for ductile metals. Applied to plastics these methods provide errors in components subjected to multi-axial tensile loads. The adjusted methods require the test results under 2D and 3D tensile loads, which cannot be gained from the uniaxial tensile tests. Scientists at the Fraunhofer Institute for Structural Durability and System Reliability LBF have improved known test specifications for the biaxial tensile test under the effect of temperature. The implemented optical measurement during the loading allows the precise acquisition of the mechanical response of the plastic sheets. The data from the new test method improves the material modelling thus providing the basis for an enhancement of the design quality of plastic components.

The International Congress of the Foundry Industry for intelligent Combining of Design, Casting, Computer Simulation, Checking and Cyclic Behavior for efficient Cast Components „InCeight Casting C8“ offers the opportunity to share experiences and knowledge of all the disciplines involved in the product life cycle of cast components. The aim is to develop a common understanding of the various requirements for high-performance and efficient cast products. From 6 to 8 March 2023 the second congress „InCeight Casting C8” will take place in Darmstadt. The Call for Papers is open until May 15, 2022.

What sustainable plastics solutions are available for automotive electronics? How exactly does optimized, high-quality polyolefin recycling work? These are just some of the questions that will be addressed at the fourth “Forum Plastic Recyclates” event to be held on March 24, 2022. Addressing topics such as the recycling market and recycling standards, using additives to improve quality and applications for recycled plastics, this year’s forum will focus once again on the field of mechanical recycling. The program and online registration form for the virtual conference are now available here. The conference fee is 250.00 euros.

How can viruses be effectively eliminated from indoor air? This question is now becoming more important as fall approaches. Efficient indoor air purification is essential, especially in schools. Fraunhofer researchers are investigating and optimizing various filter and air purification techniques in the AVATOR project.

The Forum Plastic Recyclates will now be operating, with immediate effect, under new management: All rights associated with the event have been transferred from Hanser Publications to the Fraunhofer Institute for Structural Durability and System Reliability LBF in Darmstadt. Fraunhofer LBF will now be assuming responsibility for operative planning of the event and will put together the conference program along with the experienced advisory committee. The fourth Plastic Recyclates Forum will be held on March 24, 2022. As before, the functional emphasis will be on mechanical recycling.

For optimal modelling of material properties of hard foam in FEM simulations, hydrostatic tension and compression tests are of crucial importance. These tests are essential during design to ensure that the material will not fail in the application. Researchers at Fraunhofer Institute for Structural Durability and System Reliability LBF have developed innovative test procedures and improved methods for the safe design of hard foam components.

A cost-efficient lightweight battery housing for battery electric vehicles has been developed at Fraunhofer LBF. Using this, it is possible to achieve a 40 percent reduction in weight compared to an aluminum housing. Despite the application of fiber-reinforced plastic composites, component cost is low due to a specially developed, highly-efficient manufacturing process and a stress equivalent structural design. The mechanical properties were validated in the GHOST project funded by the European Commission using finite element simulations during the design phase and validated under real conditions on a test bench. Further information will be given at JEC connect, June, 1 to 2, 2021.

Increasingly stringent statutory emission limits are pushing the automotive industry toward innovative lightweight design solutions. In this context, the fatigue strength of thin sheet metal structures, especially made from multi-material, is becoming increasingly important. As part of the EU-funded research project "ALLIANCE" on the topic of lightweight design and CO2 reduction, the car manufacturer Opel Automobile GmbH, together with the Fraunhofer Institute for Structural Durability and System Reliability LBF and the System Reliability, Adaptive Structures, and Machine Acoustics department of the Technical University of Darmstadt, has developed innovative numerical fatigue strength assessment approaches for multi-material joints based on fatigue tests of hybrid joined shear and peel specimens. The method was validated by Fraunhofer LBF scientists with fatigue tests on component-like bowl specimens with the material pairing Steel-Aluminum.

For quality control and damage assessment of injection-moulded components, simple and cost-effective tests are desired. Preparation of the standard test specimens is sometimes costly. In this case, the specimens taken from the flat areas of the component can be preferred. Scientists at the Fraunhofer Institute for Structural Durability and System Reliability LBF have improved known in-plane geometry for the shear test. Together with the modified loading schema, the new procedure is reliable and can be used for a wide range of materials. The new test specification is especially developed for SME's to reduce the costs of the component development and also by quality control. With this method, the data for material appropriate modelling can be obtained. The manufacture of special test specimens is obsolete.

Components are subject to multi-axial loadings. The typical design approach is based on material specific modelling and suitable tests to identify the parameters of the model. The tests are costly and time consuming. Scientists at the Fraunhofer Institute for Structural Durability and System Reliability LBF have suggested a basic approach to select the necessary tests for reliable modelling.