Material and process innovations –

When qualifying new manufacturing processes with resource-efficient material use, the question arises as to the reliability of components – and thus also their fatigue properties. However, studies on component fatigue often involve a considerable financial and time investment. Shorter testing times are required in particular for component validation during development or for the time-critical analysis of pilot series. Our research usually focuses on the prediction of service life or the effects of process variations on fatigue behavior.

Fraunhofer IWS has a laboratory with extensive high frequency fatigue testing equipment. It allows fatigue data to be obtained within a few days instead of a few months. Ultrasonic fatigue equipment and state-of-the-art electromagnetic resonance pulsators are available for this task. They can be used to test highly cyclically loaded structures under conditions that are close to those of actual operation. As a result, defects in castings, joints or additively manufactured components, for example, can be diagnosed and their effects on load-bearing capacity evaluated. With regard to Industry 4.0, we also develop and analyze test-based validation processes for the digital twin. We understand ourselves as bridge builders between product and process simulation and quality assurance.

Modern lightweight construction concepts in sectors such as the automotive industry or aerospace require high-performance materials. In this respect, fiber-reinforced plastic composites are particularly promising. In order to be able to cut, coat or join them with metals despite their high temperature sensitivity and severe tool wear during processing, we are developing new processing methods applying high-precision laser technology. Pulsed lasers can work on a wide variety of fiber and matrix materials. The short pulse duration allows the material to be processed "non-contact" and selectively without noticeable heating. Thermal stress on the entire component can thus be avoided.

In addition, efficient laser processes are employed to prepare fiber-reinforced plastics for further production steps. This includes, for example, surface treatment for subsequent joining, e.g. by means of adhesive bonding – or the deposition of customized protective and functional layers of metal, polymer or ceramics by thermal spraying.