Hannover Messe - Fraunhofer IWS

Online / April 12, 2021 - April 16, 2021

Hannover Trade Fair Industry

The world’s most important industrial show

www.hannovermesse.de

Fraunhofer joint booth / Digital edition

Meet us at the digital Hannover Messe!

In various magazine and talk formats, we present our research activities and solutions for industry. Visit us at the all-day Fraunhofer live stream on April 13 or on the following two days at the Hannover Messe and get into conversation with us!

Tuesday, April 13, 2021 (Fraunhofer live stream)
14.00 – 14.30	Hydrogen –Increased compeitiveness due to new manufacturing technologies for fuel cells
15:00 – 15.30	Additively manufactured rocket engine with aerospike nozzle - from conceptual design to realization
Wednesday, April 14, 2021
13.30 – 13.55	Hydrogen –Increased compeitiveness due to new manufacturing technologies for fuel cells

Additively manufactured rocket engine with aerospike nozzle – from conceptual design to realization

Microlaunchers can carry small payloads such as satellites weighing up to 350 kg and offer a particularly economical alternative to conventional launch vehicles. Previously, aerospike propulsion systems could not be implemented using conventional manufacturing processes due to the particular challenge in terms of cooling heavily stressed component regions. Fuel savings of 30 percent are theoretically possible for microlauncher applications compared to conventional engines. Together with space experts from the TU Dresden, Fraunhofer IWS firstly exploited the benefits of additive manufacturing in a geometry study for innovative cooling channels and flow-optimized fuel feeds. Next, an aerospike rocket engine additively manufactured by laser powder bed fusion (LPBF) was developed for the test stand and its function demonstrated in a hot gas test. In step three, the design and process chain will be refined within an ESA project to improve the performance further in the hot gas test.

Manifold joining expertise – from direct thermal joining and thick metal sheet laser welding to joining with reactive multilayer systems

© Fraunhofer IWS Dresden
Laser beam welding of thick sheets using the example of a crane boom.

Fraunhofer IWS is researching and developing material joints designed to last a lifetime. Aluminum, steel or even plastics are joined faster, more efficiently and with less impact on the material.

Heat:

HPCi^® joining process - joining aluminum with fiber composite plastics

The novel joining technology "HeatPressCool-integrative" (HPCi®) joins aluminum and composite plastics permanently and firmly within a few seconds. HPCi® joints can withstand tensile forces equivalent to the pressure of a hydraulic arm at up to 25 megapascals. The new joining process provides a perfect solution for lightweight aircraft construction. The technology is currently being further developed in the joint project "UTILITAS" ("Ultra-lightweight body structures for commercial vehicles in municipal service operations").

Light:

Laser beam welding of thick sheets using the example of a crane boom

In steel construction, the current value chain is characterized by complex production steps and mostly manual individual processes such as gas-shielded metal arc welding or submerged arc welding. Fraunhofer IWS researchers now present the low-distortion laser beam welding of a gapped and 4 meter long overhead crane segment with 30 millimeters sheet thickness as well as corner and butt weld joints. The laser process increases cost-effectiveness: It shortens welding times - and eliminates straightening work.

Pressure:

Joining with reactive multilayer systems (RMS) in microsystems technology

RMS provide a precisely determinable heat quantity within a few milliseconds for gentle component joining. RMS enable the joining of, for example, temperature-sensitive components and materials with different coefficients of thermal expansion. The joints exhibit excellent electrical and thermal conductivity as well as high strength. Material systems developed for RMS with a wide range of properties are used, for example, in microsystems technology.

Video: Material connections for life (YouTube)

Hardening, protecting and repairing – processes and system technology for laser beam hardening and laser cladding

© Fraunhofer IWS
Integration of the COAXwire mini in a 5-axis CNC system.

Flexibility – in the choice of tool, the process and the component geometry: Fraunhofer IWS system technology offers precisely these features.

System technology for laser beam hardening

The dynamic beam shaping system "LASSY" allows to react flexibly to different component geometries during hardening. The 1D scanner optics shape the laser beam transverse to the treatment direction. The energy distribution in the laser beam spot adapts to non-constant heat dissipation conditions by controlling the scanning speed and/or tracking the laser power. As a result, a uniform hardening depth can be achieved, for example, despite locally varying component thickness. This technology is used in laser edge refinement processes such as laser beam hardening, remelting or alloying. The system integration "E-MAqS", a camera-based temperature monitoring system providing enormous process control improvements, and the temperature control system "LompocPro" optimally round off the system technology portfolio.

System technology for laser cladding with powder and wire COAXn

COAXn stands for a modular system of coaxial processing heads for laser cladding processes. Standardized individual components allow the quick use of the optimum processing head for the specific application. The desired laser type, optics configuration and machine system are all taken into account, as well as the accessibility, precision and application rate of the material to be processed. Additional equipment such as cameras and sensors enable monitoring of the processing head/application process and the recording, processing and networking of relevant digital process data. The patented COAXwire mini fine-wire laser optics can even process fine wires with a diameter of 0.1 to 0.6 mm. Based on the coaxial three-beam principle, it enables precise and direction-independent processing in all technically common welding positions.

Video: Tailored solutions in thermal surface technologies (YouTube)

One stop solutions for fuel cell production

In the context of the hydrogen economy and electrification in the mobility sector, fuel cells are an advantageous solution for decentralized CO₂-free power supply. What is currently needed are both low-cost fuel cell stacks and production concepts suitable for mass production. Metal bipolar plates currently offer the greatest potential in terms of cost, weight and installation space. The Fraunhofer IWS (coating and joining) and the Fraunhofer IWU (forming) are working on solutions for the economic production of these metallic bipolar plates by consistently implementing a roll-to-roll (R2R) production process that is particularly cost-effective and suitable for mass production. In addition, Fraunhofer IWU and Fraunhofer IPT are developing production concepts for fuel cells for industrial purposes.

Trade fairs

Online / April 12, 2021 - April 16, 2021

Hannover Trade Fair Industry

Meet us at the digital Hannover Messe!

Our topics at Hannover Trade Fair Industry 2021 – Digital Edition

Additively manufactured rocket engine with aerospike nozzle – from conceptual design to realization

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Manifold joining expertise – from direct thermal joining and thick metal sheet laser welding to joining with reactive multilayer systems

HPCi^® joining process - joining aluminum with fiber composite plastics

Laser beam welding of thick sheets using the example of a crane boom

Joining with reactive multilayer systems (RMS) in microsystems technology

Privacy warning

More information

Hardening, protecting and repairing – processes and system technology for laser beam hardening and laser cladding

System technology for laser beam hardening

System technology for laser cladding with powder and wire COAXn

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More information

One stop solutions for fuel cell production

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More information

Contact Press / Media

Dipl.-Ing. Tobias Naumann

Contact Press / Media

Dr. rer. nat. Ralf Jäckel

Online / April 12, 2021 - April 16, 2021

Hannover Trade Fair Industry

Meet us at the digital Hannover Messe!

Additively manufactured rocket engine with aerospike nozzle – from conceptual design to realization

Privacy warning

Manifold joining expertise – from direct thermal joining and thick metal sheet laser welding to joining with reactive multilayer systems

HPCi® joining process - joining aluminum with fiber composite plastics

Laser beam welding of thick sheets using the example of a crane boom

Joining with reactive multilayer systems (RMS) in microsystems technology

Privacy warning

Hardening, protecting and repairing – processes and system technology for laser beam hardening and laser cladding

System technology for laser beam hardening

System technology for laser cladding with powder and wire COAXn

Privacy warning

One stop solutions for fuel cell production

Privacy warning

HPCi^® joining process - joining aluminum with fiber composite plastics