Projects

A technology platform is being developed to generate realistic rubber abrasion, which will be analyzed for material and tire development and used to forecast digitized driving analysis. This requires the development of a parametric friction surface and the generation of real reference particles. The degradation of the realistic abrasion produced is being investigated using new laboratory weathering techniques and chemical analyses. The results are being used for ecotoxicological assessments and also transferred to vehicle fleet simulations.

The icing of aircraft wings, especially on the leading edge, impairs aerodynamics and jeopardizes the safety and efficiency of flight operations. Conventional thermal de-icing systems are energy-intensive and incompatible with emission-free aircraft engines. In the EU project “UP-Wing” (Clean Aviation Innovation Program), Fraunhofer LBF is developing an innovative electromechanical de-icing system based on structural dynamic vibrations.

Building insulation made from renewable raw materials has been state of the art for many years, but still accounts for only a small share of the insulation market because it has disadvantages compared to mineral products and foamed plastics, e.g., in terms of fire behavior, or because it is not available in the form of self-supporting panels. In the joint research project “OrganoPor_Fassade” funded by the German Federal Ministry for Economic Affairs and Climate Action (BMWK), experts from Fraunhofer LBF have further developed new bio-based, halogen-free, flame-retardant, self-supporting insulation boards that can be integrated into a composite thermal insulation system.

Passive hand prostheses with articulated fingers are often attractive to end users due to their low cost. The Fraunhofer Cluster of Excellence Programmable Materials (CPM) is developing a finger for a hand prosthesis that can assume four stable deformation states. The Fraunhofer LBF, IWM, ITWM, and IAP are collaborating on the “ProFi” project to replace the previous multi-part, screw-fastened solution with a single programmable metamaterial in order to reduce assembly costs. This has been achieved with a joint structure that has only one degree of rotational freedom and a small bending radius and is interconnected with bistable unit cells.

Components made of zinc die-cast alloys are used in various industries due to their high surface and component quality and the efficiency of the hot-chamber die-casting process. However, they are rarely used for components subject to high cyclic loads because they lack structural durabiity characteristics. To change this, the cyclic material behavior of various zinc die-cast alloys was investigated and summarized in a design concept.

In the “FOLAMI” research project, Fraunhofer LBF focused on evaluating mixed steel and aluminum joints produced by form-fitting laser beam welding for durable semi-finished products in shipbuilding. Accompanying the welding process development, numerical and experimental investigations were carried out to verify the structural durabiity, initially at the sample level and then for specifically optimized adapters as connecting elements between steel and aluminum structural elements.

Battery solutions for ships are usually tailor-made and, if at all, for small series, which leads to high costs. In addition, a single battery type is used both to cover the high energy requirements, e.g., to maintain cruising speed, and for high power peaks, e.g., when loading in port. However, a single cell technology cannot meet both requirements. As a result, batteries are oversized by a factor of 2 to 10, which also leads to high costs. The EU joint project SEABAT has developed a hybrid concept based on the combination of high-energy and high-performance batteries with a novel converter concept.

In the PEMPAR project, we are developing a measurement methodology for parameterizing models that simulate temperature and humidity effects as well as mechanical loads on PEM. Data gaps are being closed and the testing times for PEM, fuel cells, and electrolysers are being shortened. The focus is on the recording of time-dependent water absorption, thermal and hygric coefficients of linear expansion, and the viscoelastic material properties under various conditions.

The ORka3D research project—optimization of resource use in welded structures through automated in-line service life assessment based on 3D scans—aims to develop an automated process for evaluating weld seam quality and the associated fatigue strength. This simplifies and improves quality control, as potential weak points can be identified and rectified immediately after production. The project aims to ensure consistent product quality while reducing costs.

Galley kitchens in commercial aircraft are central components of modern passenger aircraft. The future use of alternative energies for engines will lead to a significant reduction in the energy available in the cabin by 50%. Such a significant energy saving is only possible through a leap in innovation in catering equipment. In the GECO (Galley Efficient Catering Operation) project, the aircraft galley is being embedded in a new centralized system context, enabling the linking of process chains and the networking of previously stand-alone systems to unlock new synergies. Structural improvements with integrated solutions reduce weight and energy consumption in the aircraft galley, while manufacturing processes are also being rethought against the backdrop of a holistic product life cycle. The use of sustainable materials contributes to the goal of improving environmental auditing.