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Failures in industrial production processes result in costs. It is therefore all the more important to completely monitor these processes. Such an approach allows for early detection of changes in the processes or the manufactured components. At Fraunhofer IWS researchers are developing novel concepts for a high-performance process monitoring. They use artificial intelligence (AI) to access relevant process information, analyze it in real time and use it for quality assurance.

A team of interdisciplinary researchers led by Dr. Benjamin Schumm from the Chemical Coating Technology group has developed “DRYtraec^®“ to produce battery electrodes in a more environmentally friendly way, at lower cost and with less energy input than before. This new dry coating process has the potential to revolutionize the production of electrodes for electric car batteries and similar energy storage devices.

Fraunhofer IWS is working on a new evolutionary stage of reactive joining. In future, reactive multilayer systems (RMS) will join sensors and other components in the field of microsystems engineering as direct coating on wafers and components or as thin films in a particularly gentle and environmentally friendly way - using less energy and yet much faster than the joining technologies used so far.

Advanced thermal spraying, welding and additive manufacturing technologies are set to aid the breakthrough a highly fuel-efficient alternative rocket engine for profitable small satellite missions. The technology in question is an aerospike engine. Such engines could reduce fuel consumption by one-third for many rocket launches, thus improving the environmental and financial costs of space travel.

Functionalized fiber-reinforced plastic composites are to replace metals – that is the goal of the team headed by Manuel Reif. The researcher from the Thermal Spraying group has now been awarded the Oerlikon Metco Young Professionals Award for his research in lightweight construction. The scientists have developed a solution for functionalizing fiber-reinforced plastic composites so that they can also be used in applications previously dominated by metals. Using the example of an aircraft wing, they demonstrated how thermal spraying can be successfully used to apply multilayer heating systems and reduce weight at the same time.

In the course of the digital revolution, numerical simulation and calculation methods are taking on a decisive role in all product lifecycle stages. In order to develop structurally relevant products for the automotive and aerospace industries as well as for medical and energy technologies, it is necessary to have a holistic strategy with particularly close inter¬linking between virtual and real worlds.

Fuses, modules and interconnect cables are widely used in many different technical environments – applications range from inside conventional control cabinets to space. While the automation degree in fabricating various technical components is increasing, wiring remains a laborious and error-prone manual process. Researchers at Fraunhofer IWS, together with partners such as AIRBUS, are developing processes to manufacture conductive paths in a cost-efficient and safe manner.

Many people associate steel construction technology with manual welding and glaring arcs. In order to manufacture large-scale, highly stressed steel structures such as overhead cranes or wind turbine towers in line with high quality standards, exten¬sive technical expertise and efficient processes are required. High-energy, modern joining processes such as laser beam welding will revolutionize steel construction in the coming years. A research project conducted over the past 2.5 years on low-distortion and low-energy laser beam welding for thick-walled steel structures follows precisely this goal.

Already in the early stages of component development, standardized characteristic values are indispensable for the selection of materials. However, as development advances, focus shifts to application-oriented load scenarios. At Fraunhofer IWS, these scenarios can be transformed into individual test procedures by directly linking process knowledge and material understanding.

The new material class of high-entropy alloys (HEA) promises many innovations in aviation, turbine and tool construction as well as other industries. Testing the countless variations in the chemical composition of this material class would require research and development lasting thousands of years. Researchers at Fraunhofer IWS have further enhanced methods for material design that will enormously accelerate this work.