Technologies

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.

Thermodynamic calculations allow predictions about phase formation in materials during thermal processes, both during their manufacturing and under application conditions.

DIGITAL FINGERPRINT: FORGERY-PROOF IDENTIFICATION OF COMPONENTS | Digital production requires individual component identification, as this is the only way to digitally link production data with the physical components. Optically readable codes such as barcodes or matrix codes are established methods for recording and tracking components in production and logistics. However, these methods are subject to fundamental limitations in terms of the space required, the surface geometry and structure of the component, as well as the robustness of the marking against damage and manipulation. They are also easy to counterfeit and are therefore only suitable as a security feature to a very limited extent. Last but not least, in some cases modifications to the surface are undesirable, whether for functional, hygienic or aesthetic reasons. This is where Fraunhofer IFAM's fingerprinting process comes in.

Nowadays, products such as adhesives, potting resins and matrix resins for fiber composites or coatings not only have to meet high technical and ecological standards, but also be economical and sustainable. The basis for meeting these requirements is already laid in the raw materials. At Fraunhofer IFAM, the development of novel raw materials, such as reactive polymers or additives, is therefore a focus of research and development work. The raw materials developed are tested in application-oriented formulations and specific applications. In addition, sample formulations based on new raw materials are developed at the institute, often also on direct order from raw material manufacturers.

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.

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.

TESTING LABORATORY FOR PAINTS, COATINGS AND CORROSION | In the development of paints and coatings as well as the accompanying quality management, standardized suitability tests of the paint are necessary in order to obtain the most accurate characterization of the coating system. Fraunhofer IFAM offers a wide range of test methods to determine and verify adhesion, elasticity, hardness, chemical resistance, and weather resistance. Paint testing is carried out both on liquid paints and on cured coatings. Depending on the application, these are subjected to varying loads – under laboratory conditions or in outdoor weathering. For this purpose, the researchers use standardized test procedures, but also develop customized test and testing methods if required.

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.

We cover the complete value chain for the additive processes we have available at Fraunhofer IFAM – from the creation of 3D data models, through manufacturing, to final processing and inspection of the components.

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.