Technologies

The "Center for Surface and Coating Technology" at Fraunhofer IFAM demonstrates the future of surface treatment. The state-of-the-art technical center has digitally linked industrial robots – such as painting robots – for the automated cleaning, pre-treatment, and subsequent painting of component surfaces in small and large structures. The entire process chain is digitally mapped and supplemented by interaction options using virtual and augmented reality. R&D goals include the realization of digitally networked surface technology systems and processes as well as process and quality optimization through machine learning and the use of AR/VR methods.

Corrosion is one of the greatest challenges for industry, infrastructure, and the environment. According to DIN EN ISO 8044:2025, corrosion is defined as the “chemical or electrochemical interaction between a material, usually a metal, and its environment.” This interaction can lead to material damage, functional failure, and enormous economic costs. In industrialized nations, 3-4% of gross domestic product is lost annually due to corrosion damage. The fact is that most of this corrosion damage could be avoided if existing knowledge were applied properly. Fraunhofer IFAM offers comprehensive solutions for corrosion protection, testing methods, and damage analysis – scientifically sound and accredited.

In the group Soft Magnetic Materials, innovative powder technologies are used to manufacture soft magnetic components with reduced losses or special property profiles. Different concepts are pursued depending on the requirements especially the frequency range.

The aging of bonded joints begins immediately with their manufacture. External stresses are decisive for their speed and thus their significance for the bonded component. The visible or measurable manifestations of aging are very diverse. For example, the glass transition temperature can decrease due to the degradation of polymer structures or increase due to plasticizer diffusion as well as incorporation of stiff molecular structures into the polymer chains. Specific functions of the adhesive, e.g. conductivities or damping, may deteriorate and / or the bond strength may drop. At Fraunhofer IFAM, we are investigating the aging of adhesives in order to sustainably improve/ensure the longevity of bonded joints.

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.

Green hydrogen is considered a key building block of the energy transition. At the same time, existing electrolysis processes face major challenges: hydrogen production is still costly and energy-intensive and requires highly purified water. This is exactly where the SeaEly project came in. Together with partners from research and industry, the Fraunhofer IFAM developed new components and testing methods for direct seawater and brackish water electrolysis. The aim was to enable efficient hydrogen production even with challenging water qualities — without the need for complex desalination processes.

YOUR GRID CONNECTION DOES NOT ALLOW FAST CHARGING? | At Fraunhofer IFAM, simulation calculations can be used to consider and analyse the effects on the entire energy system associated with the installation of charging infrastructure.

REAL LABORATORY WITH CHARGING STATIONS, STORAGE SYSTEMS AND PHOTOVOLTAIC SYSTEMS | Charging electric vehicle fleets at companies or public institutions without smart charging management can result in enormous costs or even overload the grid connection. To avoid this, the industry is turning to “smart charging.” This allows charging processes to be controlled in a way that meets demand and optimizes costs. The real laboratory at Fraunhofer IFAM offers the opportunity to test, analyze, and specifically develop such solutions under real-world conditions.

RAY TRACING FOR OPTIMIZED SURFACE TREATMENT WITH LIGHT | The irradiation of surfaces with light is a common procedure in surface technology. It can be used, for example, to clean or activate surfaces before the adhesive bonding or coating process. Currently, there is also great interest in the disinfection of surfaces with UV light. In order to design and optimally configure irradiation systems, researchers at Fraunhofer IFAM simulate light distribution and intensity with an algorithm that has recently gained publicity for its application in 3D computer graphics: ray tracing.

INLINE-BLASTING PROCESSES FOR CLEANING, ACTIVATION AND REPAIR OF SURFACES | Classical compressed air blasting requires the use of blasting booths or complex temporary protective measures to clean surfaces or remove coatings. Much simpler is to use compact and mobile vacuum suction blasting prior to, for example, adhesive bonding, painting/lacquering, coating, or repair work. In this method an industrial vacuum system generates a reduced pressure in a closed head through which the abrasive is accelerated onto the surface and after the blasting process is immediately extracted again. This means that dust-free blasting processes can even be performed in-line under sensitive production conditions.