Technologies

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  • DRY PRODUCTION OF POLYMER-BASED SOLID-STATE ELECTROLYTES | The solid-state battery (ASSB) is one of the next-generation technologies that could replace conventional lithium-ion batteries in the future due to its high energy density. The current challenge is scaling up the manufacturing processes for the individual battery components (e.g. the solid-state electrolyte). Fraunhofer IFAM is researching the solvent-free and therefore dry process route of polymer-based solid-state electrolytes by means of extrusion. The continuous mode of operation promises to implement an uninterrupted processing method in production chains. In addition, extrusion not only offers the possibility of producing on a kilogram scale, but also of reducing potential process costs by eliminating subsequent drying steps.

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  • DETERMINATION OF REACTION ENTHALPIES OF MOISTURE-SENSITIVE MATERIALS UNDER INERT GAS ATMOSPHERE | The enthalpy measurement of mixing reactions during the synthesis of air-sensitive materials must be carried out under inert conditions and thus places special demands on the measurement setup. One example of moisture-sensitive materials are sulfide solid-state electrolytes, which may be used in future solid-state batteries (ASSBs). To make these materials economically attractive, Fraunhofer IFAM is researching the scale-up of the synthesis process. For the upscaling of the syntheses, reaction enthalpies are required, which must be measured in an inert gas atmosphere.

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    ADHESIVE FILMS AND COATINGS BASED ON BENZOXAZINE - STORAGE-STABLE AND NON-MELTABLE | Repairing fiber composite components is often time-consuming and requires multiple processing steps and curing cycles of the resin. Typical restoration of the function or appearance of a damaged area is carried out using a wet lamination process or application of reinforcing structures on the surface. Therefore, if an adhesive film or coating based on benzoxazines is used instead this enables comparatively simpler repair and adhesive bonding, with final strength being achieved within 30 minutes.

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  • Testing of aquaculture net coatings
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    Testing of aquaculture net coatings on the Helgoland test rig for static fouling tests, with high-pressure cleaning to check mechanical stability and cleaning success

    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.

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    MECHANICAL TESTING, COMPONENT SIMULATION AND TESTING OF BONDED JOINTS | Fraunhofer IFAM has a materials testing laboratory certified according to DIN EN ISO 9001:2015. This laboratory is accredited according to DIN EN ISO/IEC 17025:2018 for the procedures specified in the DAkkS certificate. Experiments are carried out to test materials, structures and, in particular, adhesively bonded joints according to standardized and self-developed procedures for example for the automotive industry or rail vehicle construction. The results of these tests form the basis for simulating component behavior. Many of the tests focus on the tensile behavior of fiber-reinforced plastics, but also on the impact strength and peel strength of adhesively bonded joints. Particularly in order to describe the complex behavior of adhesively bonded joints, the researchers also develop customized test methods as required.

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    Functionalisation of large components with robots and multi-axis portal systems

    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.

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    FUNCTIONALIZATION OF COMPONENTS USING PRINTING TECHNOLOGIES | For customized functionalization of components using printing technologies, suitable inks and pastes are required. Fraunhofer IFAM has extensive expertise and capabilities for the development of printable inks and pastes. These range from the selection of suitable functional and additive materials, to the production / homogenization of the pastes and inks, to the subsequent printing and curing process.

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  • PLASLON-Antihaftbeschichtung
    © Fraunhofer IFAM

    PLASLON-Antihaftbeschichtung

    Non-stick coatings have been among the most popular coatings for cookware such as pans, casseroles or cutlery for decades due to their ease of use and cleaning. Common nonstick coatings are made with a PTFE or sol-gel base. However, PTFE-type coatings face a ban in the near future due to possible PFAS restrictions by the EU. In addition, these coatings have only limited durability and lose their non-stick effect over time. In addition, they are not very stable mechanically and have to be baked in an oven, which involves high energy consumption. New, sustainable solutions with good non-stick properties are therefore needed. Researchers at Fraunhofer IFAM have developed PLASLON® coating, a PFAS-free alternative, which is characterized by its excellent non-stick properties in combination with its high durability.

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  • Temperature-controlled tensile tests in the temperature range between -170 °C and 200 °C with local strain measurement.
    © Fraunhofer IFAM

    Temperature-controlled tensile tests in the temperature range between -170 °C and 200 °C with local strain measurement.

    The new cryogenic testing machine of Fraunhofer IFAM enables to determine the material and small component properties of polymers, composites, and adhesive joints at cryogenic temperatures.

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    Peeling off the PeelPLAS® release film from a component made of glass-fiber-reinforced plastic (GRP) that has been painted with a gelcoat in the mold.

    MANUFACTURING OF FRP COMPONENTS USING A FUNCTIONALIZED RELEASE FILM | Due to their low weight and strength, components made of fiber-reinforced plastics (FRP) are in particularly high demand in a wide range of industries, such as the aerospace or automotive industries. However, conventional demolding of FRP components by using release agents is very cost and labor intensive. In addition, the release agents can have harmful effects on the environment. At Fraunhofer IFAM, a plasma-coated release film has been developed which allows thermoset plastic components to be manufactured and safely demolded without the use of release agents. The component surface is free of contamination and can be painted or bonded directly.

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