Technologies

PLASMA AND LASER PROCESSES: THE ENVIRONMENTALLY FRIENDLY WAY OF SURFACE TREATMENT | Resource- and environmentally friendly processes are more in demand than ever. The functionalization of components using completely dry techniques based on the plasma or laser processing enables to slash the use of wet chemicals such as solvents, primers and rinsing media. This significantly improves the CO2 footprint of manufacturing processes and products. Fraunhofer IFAM is currently researching versatile applications of plasma and laser technologies for the pretreatment and functionalization of a wide range of technical surfaces such as metals, polymers, and glass for various industrial branches.

EFFICIENT PLASMA COATING WITH CUSTOMIZED NOZZLES | Inline Coating with Atmospheric Pressure Plasmas has established itself as a sustainable solution in industrial manufacturing. This technology offers, for example, environmentally friendly corrosion protection and enables secure adhesion of adhesives and paints – all without the use of harmful primers. Each industrial application scenario presents individual challenges: from coating width and accessibility of complex, three-dimensional components to the treatment of temperature-sensitive materials. At Fraunhofer IFAM, customized nozzle heads are developed to flexibly address these varying requirements.

PLASMA COATINGS: CHEMICAL-FREE THIN FILMS FOR NEW SURFACE AND PRODUCT PROPERTIES | The demand for special functional coatings for products and semi-finished products is very high in many industrial sectors - from automotive production and plastics processing to medical technology or biotechnology. Fraunhofer IFAM is researching and developing plasma-assisted coating processes which decisively improve the range of properties of these (semi-finished) products almost independently of the material used. And without the use of chemicals! This makes these processes particularly interesting at present, because it helps companies to comply with regulations such as the REACH regulation or the HSE guidelines.

ENVIRONMENTAL SIMULATION FOR TESTING AND INSPECTION OF ANTI-ICE COATINGS | For the characterization of surfaces, laboratory tests under reproducible icing conditions are necessary to investigate ice formation and ice adhesion strength. This provides material developers with initial information on the performance of the surfaces. Fraunhofer IFAM determines the potential of newly developed icephobic coatings in application-specific laboratory tests.

In the corrosion testing laboratory at Fraunhofer IFAM, various test methods are available for you - for aviation, as well as for automotive and maritime technologies, and for all other applications in which corrosion protection is important. Thus, you benefit not only from the expertise of our personnel in the field of corrosion protection, but also from the diversity of our capabilities.

In today’s world, where resource conservation and sustainability are increasingly important, powder technology plays a crucial role in recycling and the circular economy. Whether metallic residues, powder waste from additive manufacturing, filter dusts, or even complex hybrid materials: what was often considered hard-to-recycle waste can be transformed at Fraunhofer IFAM into new, value-added materials and components using powder technology processes. The key advantage: powder technology enables the direct use of recycled materials – even when they are not spherical, fine powders.

Fraunhofer IFAM has now developed a novel solution for the dynamic improvement of the kinematics: the hybrid drive for industrial robots.

FUNCTIONALIZABLE METAL SURFACES THROUGH PLASMA ELECTROLYTIC OXIDATION (PEO) | Plasma electrolytic oxidation (PEO), also known as micro arc oxidation (MAO), is a wet chemical process that enables the production of highly functionalizable oxide layers on metals whose oxides do not have electrical conductivity, such as aluminum, magnesium, or titanium. These coatings are hard, wear-resistant, heat-resistant, and porous, making them ideal for use in aerospace, medical technology, and other high-performance industries.

Fraunhofer IFAM has been working on electromobility and the casting of electric drive components since 2008. The focus is on the development and testing of new casting concepts and design methods for electric motor castings. The field of expertise has been expanded to include the analysis and evaluation of castings for the body construction of electric vehicles, with a particular focus on giga-casting.

RELIABLE IDENTIFICATION OF CAST COMPONENTS | The reliable identification of castings is an attractive goal in many respects. For example, it permits the unambiguous assignment of production parameters to a specific component and thus enables quality documentation, as is increasingly required not only in the aerospace industry. In addition, it forms the basis for process control based on the individual component, as is being pursued in the context of Industry 4.0 approaches.

BRINGING NOVEL MATERIALS INTO PRODUCTION! | The field of "Core and Mold Materials" at Fraunhofer IFAM focuses on a wide range of research topics relating to materials and their processes for casting. The demand for higher functional integration in cast components and the associated increase in component complexity on the one hand, and the demand for sustainable, energy-saving processes on the other, is continuously increasing. Both require the development of new core and mold materials and their processes in the world of casting and its products.

"INTELLIGENT" CAST COMPONENTS FOR THE AUTOMOTIVE INDUSTRY, URBAN AIR MOBILITY AND MANY MORE | Materials, components, and structures with a certain degree of inherent "intelligence" are a central research topic at Fraunhofer IFAM. A typical field of application is the monitoring of mechanically loaded components in operation in all its gradations: from simple load monitoring to damage detection and localization to the prediction of the remaining component lifetime. The basis of such capabilities is a technical nervous system that detects loads and thus provides a basis for their evaluation: sensors.

SIMULATION AND MODELING OF CASTING PROCESSES | An important step for every casting development is the process simulation, in which the design of the casting itself, but also of the mold, is checked for production-compatible design and optimized if necessary. By mapping the entire casting process and subsequent solidification in detail, we can identify areas where casting defects are most likely to occur. The accompanying simulation significantly shortens development times and in many cases enables practical test series to be saved or reduced through realistic mapping of processes and procedures. In the sense of a digital twin, it can also be used for process monitoring and control.

In the area of casting technology, Fraunhofer IFAM has a broad technology portfolio for a wide range of industrial applications. This includes equipment in the following areas: Die casting / Squeeze casting, low pressure die casting, investment casting and gravity casting.

SHORT PROCESSING TIMES THANKS TO HYBRID CASTINGS - IDEAL FOR LIGHTWEIGHT CONSTRUCTION | The field of "hybrid casting" deals with novel joining technologies using cast components. Directly integrated metallic structures or also plastics or fiber structures are used to realize a multi-material design. Directly during the casting process of the metal component, the possibility of material joining is given. This allows innovative components to be realized with savings in production steps, bringing with them various advantages.

With its expertise in the field of casting technology, Fraunhofer IFAM supports industrial customers in the casting technology implementation of an idea from the concept to the first prototype to the applicable product. Different casting processes and materials are available suitable for the respective problem.

TARGETED PRODUCT IMPROVEMENTS BASED ON IN-DEPTH KNOWLEDGE OF FRICTION AND WEAR | Whether motors and pumps as a whole or their seals - almost every application product is affected by friction and wear. The consequences are high energy losses and a shortened service life of the products. To counteract this, Fraunhofer IFAM is working intensively on tribology, i.e. the question of how friction and wear can be reduced or how lubrication between components can be improved. This is because these factors are directly influenced by various things such as material selection, surface coating, or contact geometry. With its broad spectrum of competencies in the fields of materials research, coating technology and analytics, the institute offers ideal conditions for developing holistic tribological solutions.

DETERMINATION OF MATERIAL AND SMALL COMPONENT PROPERTIES OF POLYMERS, COMPOSITES, AND ADHESIVE JOINTS AT CRYOGENIC TEMPERATURES | Fraunhofer IFAM offers outstanding possibilities for material testing at extremely low temperatures. In addition to tests in liquid nitrogen at -196°C, we can also carry out tests in gaseous nitrogen at temperatures down to -180°C.

MORE FLEXIBILITY THROUGH MORE AXES | The use of industrial robots and 5-axis gantries systems makes it possible to print functions such as sensors or heaters on components with complex surfaces exactly where they are needed. Various printing technologies such as aerosol jet or dispensing can be used to print structure sizes ranging from a few micrometres to several metres. The systems at Fraunhofer IFAM can thus provide component sizes ranging from a few millimetres to 10 metres with a variety of different functions, such as conductor tracks, with pinpoint accuracy.

FUNCTIONAL INTEGRATION THROUGH PRINTING TECHNOLOGIES | The technology platform »Functional Printing« comprises digital and mask-based printing technologies, with which components can be functionalised specifically and precisely at the required component locations. Sensors or electronic components can thus be integrated into existing products and give the component additional or completely new properties and functions. Fraunhofer IFAM offers all important printing processes at its disposal and has in-depth material expertise. If printable inks or pastes are required for sensory applications, for example, which are not commercially available, these can be developed at Fraunhofer IFAM.

POWDER METALLURGICAL AND CASTING PRODUCTION OF POROUS METALS | Metal foams, porous metals and hybrid materials based on them have an attractive range of properties due to their specific structures. They are used in many areas such as automotive engineering or medical technology to improve technical systems. The Fraunhofer IFAM offers various powder metallurgical and casting processes for the production of open- and closed-cell metal foams.

INTEGRATION OF HIGHLY ELECTRICALLY AND THERMALLY CONDUCTIVE FILLERS IN A PLASTIC MATERIAL | Fraunhofer IFAM is specialized in the compounding of highly filled special polymer composites and the further processing into printable composite filaments. For the processing or production of filaments from polymer composites, the institute has comprehensive know-how and the latest technologies and process techniques. The composition of the material (fillers, filler content) and the selection of the base polymer are customized according to the customer's specific requirements.

DO YOU NEED CERTAIN PROPERTIES OF A METAL IN A PLASTIC? | Then Fraunhofer IFAM offers the solution with its developed polymer composites! The special compound technology of Fraunhofer IFAM makes it possible to produce special composites based on a wide range of thermoplastics and elastomers which are, for example, highly electrically and/or thermally conductive.

KEY TECHNOLOGY FOR EMC PROTECTION AND CAMOUFLAGE TECHNOLOGY | Radiation-absorbing materials (RAM) are becoming increasingly important in numerous industries. Whether in military technology, measurement technology, or automotive engineering - wherever sensitive electronics and high-precision sensors are used, effective protection against electromagnetic interference (EMI) is essential. Modern composite materials offer tailor-made solutions that can both shield electromagnetic waves and minimize radar and sensor signatures.

THIN SEPARATORS MADE OF SULFIDE OR POLYMER USING A SLOT DIE | Solid-state batteries with high energy density require thin separators made of sulfides or polymer electrolytes with layer thicknesses of less than 30 micrometers. With slot die coating, we can apply slurry tailored precisely to requirements and produce separator layers. The production and characterization of these layers requires expertise in materials, processes, and analytical methods, which are bundled at Fraunhofer IFAM.

With the steady increase in electronic assemblies and their use, for example in motor vehicles and sensors, the demands on their long-term stability and functional reliability are also rising. Polymer potting is an ideal way to protect these components.

Metal injection molding (MIM) is the key process when it comes to the economical series production of high-precision, complex metal components. MIM combines the design freedom of plastic injection molding with the mechanical properties of metallic materials. Fraunhofer IFAM has been one of the leading research institutions in this field for over 30 years and supports industry partners in implementing innovative material and component solutions in new products.

HIGH-PERFORMANCE COMPOSITES FOR RELIABLE ELECTROMAGNETIC COMPATIBILITY | Electronic systems are everywhere – from complex machine controls and sensor technology in Industry 4.0 to electric drives in vehicle construction. This also increases the risk of electromagnetic interference that can affect other devices or cause sensitive systems to malfunction. Compliance with electromagnetic compatibility (EMC) is therefore essential for the trouble-free functioning of devices and the reliability of sensitive electronic equipment. At Fraunhofer IFAM, we develop innovative functional composites for EMC protection.

VUV RADIATION OPTIMIZES SILICONE PROPERTIES AT THE SURFACE | We encounter silicone elastomers in many different areas. Due to their high elasticity, very good temperature resistance and biocompatibility, they are suitable for a wide variety of applications, for example in medical or food technology. The surface properties of the material, on the other hand, are not ideal and make it difficult to use in certain applications. For example, silicones are susceptible to wear, attract dirt, and can only be bonded to a limited extent. At Fraunhofer IFAM, a process has been developed which allows the surfaces to be modified quickly and flexibly without impairing the excellent mechanical properties of the silicones.

INNOVATIVE SOLUTIONS FOR SUSTAINABLE COOLING TECHNOLOGIES | Magnetocaloric cooling systems offer industry a pioneering alternative to conventional compression refrigeration machines – technologically innovative, economically attractive, and ecologically sound. Instead of conventional refrigerants, these systems use the magnetocaloric effect: By making targeted changes to the magnetic field in specially developed materials, cold can be generated efficiently and in a controlled manner – without the use of fluorinated greenhouse gases.