Technologies

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.

LASER TECHNOLOGY ENABLED STABLE INTERFACES FOR METAL HYBRID CASTING AND PLASTIC INJECTION MOLDING TO INCREASE COMPOSITE STRENGTH | Laser technology offers optimal possibilities for the pre-treatment of surfaces. Researchers at Fraunhofer IFAM have succeeded in achieving a significant increase in composite strength in metal-metal, metal-plastic or plastic composites by means of laser pre-treatment. The high interfacial strengths result from positive and non-positive micro-interlocking between the laser-treated component and the infiltrated metal or plastic. Innovative laser-induced channels on components, which enable complete infiltration with melts or plastics, are fundamental. In addition, production time and costs can be saved compared to conventional joining methods by integrating the joining process into the primary forming process.

SELF-HEALING COATINGS – FOR SUSTAINABLE PROTECTION AND EXTENDED DURABILITY | Self-healing coatings represent an innovative approach to protecting surfaces against wear and damage over the long term. These intelligent materials can repair minor damage in coating layers either autonomously or through external stimuli such as temperature changes, humidity, or UV light. The technology offers versatile applications, particularly for reducing maintenance costs and extending the lifespan of coated surfaces.

RESIDUE-FREE AND DRY CLEANING OF COMPONENTS | Contaminants and release agents can be removed from components using CO2 snow blasting processes. This in-line technique involves the sudden expansion of liquid CO2, whereby solid crystals of CO2 snow form in a nozzle on introducing compressed air. These are blasted at the surface to be cleaned. There is no damage due to the immediate sublimation, and even sensitive surfaces can be effectively cleaned. Compared to conventional blasting grit, the CO2 snow evaporates and can be extracted without leaving residues. The process is eco-friendly because CO2 can be recovered as a byproduct from many chemical processes.

BIOCIDE-FREE FOULING PROTECTION AND FLOW-OPTIMIZED SURFACES FOR THE MARITIME INDUSTRY | Functional coatings against biofouling and corrosion are an important part of the maritime industry. They protect ships and other maritime infrastructure in the harsh marine operational environment.. Innovative coating technologies and materials are being researched at Fraunhofer IFAM to achieve effective and durable resistance to biofouling, corrosion, and mechanical abrasion, for example by underwater cleaning processes. This can reduce operating costs, extend service life and improve environmental protection. The development of high-performance antifouling coatings is an important step towards a sustainable maritime industry, which in the future will focus, among other things, on the climate neutrality of ships and the expansion of renewable energies at sea.

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.