Projects

Elastomer failure needs to be detected quickly and easily — but how? Due the variety of failure patterns that occur on elastomer components, it is not always easy to establish the exact cause of a failure. In the internal Fraunhofer project, AI Failure Analysis of Technical Elastomers, researchers are exploring the possibility of objectively analyzing elasto-mer failures through artificial intelligence. The resulting process will be transferred to customer-specific applications at a later stage.

In the PEMPAR project, we are developing a measurement methodology for parameterizing models that simulate temperature and humidity effects as well as mechanical loads on PEM. Data gaps are being closed and the testing times for PEM, fuel cells, and electrolysers are being shortened. The focus is on the recording of time-dependent water absorption, thermal and hygric coefficients of linear expansion, and the viscoelastic material properties under various conditions.

The Fraunhofer PREPARE project HATE-Fluor sets new standards in materials development: The goal is to produce fluorine-free elastomers as a sustainable alternative to fluoropolymers – high-performance, durable, and environmentally friendly. The newly developed materials offer maximum chemical and thermal resistance, particularly in sealing technology, for example in hydrogen systems or photovoltaic vacuum systems. Innovative antioxidants and optimized formulations ensure maximum stability – for future-proof solutions without fluorine.

Sustainable plastic recyclates and biodegradable polymers for nonwovens and roofing membranes: 1. Is it possible to recycle and additives different waste streams to produce high-quality recyclates, which in turn can be used to produce fibers and films that can be further processed into competitive nonwovens and films for roofing membranes? 2. Can fibers be produced from bio-based polymers that can not only be spun into nonwovens, but whose degradation in the environment can be adjusted and which do not pose a risk to the environment?

The FNR project “BioFlammschutz” has developed innovative, bio-based, and environmentally friendly phosphorus-containing flame retardants. These are intended to serve as an ecologically and economically advantageous alternative to the halogen-containing flame retardant additives currently in use, which are problematic from an ecotoxicological perspective. The new flame retardants were produced from cotton and wood cellulose and the inexpensive sugar alcohol erythritol using a method developed at Fraunhofer LBF. Their suitability was demonstrated in flame retardant applications for polyolefins and a partially bio-based polyamide.

Building insulation made from renewable raw materials has been state of the art for many years, but still accounts for only a small share of the insulation market because it has disadvantages compared to mineral products and foamed plastics, e.g., in terms of fire behavior, or because it is not available in the form of self-supporting panels. In the joint research project “OrganoPor_Fassade” funded by the German Federal Ministry for Economic Affairs and Climate Action (BMWK), experts from Fraunhofer LBF have further developed new bio-based, halogen-free, flame-retardant, self-supporting insulation boards that can be integrated into a composite thermal insulation system.

Advances in the development of improved quality plastic recyclates: reduction of unwanted odors. The focus is on equipping plastic recyclates with special plastic additives, known as odor scavengers or odor control additives. The newly developed method identifies and binds volatile compounds that are responsible for unpleasant odors. In addition, the influence of the compounds investigated on material stability was examined and evaluated. These innovations are crucial, as consumers are looking for high-quality, odorless products.

Sandwich elements are increasingly being used in the façades of industrial halls and cold stores. In the ReSaMon project, the BMWK is promoting optimized production of the elements. In the project, a consortium of seven partners is developing a non-destructive and non-contact measurement technology that can identify potential weak points and changes in material properties during the production process. Fraunhofer LBF is investigating the possibilities of data-based methods for detecting and localizing defects in conjunction with the developed measurement technology.

Battery solutions for ships are usually tailor-made and, if at all, for small series, which leads to high costs. In addition, a single battery type is used both to cover the high energy requirements, e.g., to maintain cruising speed, and for high power peaks, e.g., when loading in port. However, a single cell technology cannot meet both requirements. As a result, batteries are oversized by a factor of 2 to 10, which also leads to high costs. The EU joint project SEABAT has developed a hybrid concept based on the combination of high-energy and high-performance batteries with a novel converter concept.

Galley kitchens in commercial aircraft are central components of modern passenger aircraft. The future use of alternative energies for engines will lead to a significant reduction in the energy available in the cabin by 50%. Such a significant energy saving is only possible through a leap in innovation in catering equipment. In the GECO (Galley Efficient Catering Operation) project, the aircraft galley is being embedded in a new centralized system context, enabling the linking of process chains and the networking of previously stand-alone systems to unlock new synergies. Structural improvements with integrated solutions reduce weight and energy consumption in the aircraft galley, while manufacturing processes are also being rethought against the backdrop of a holistic product life cycle. The use of sustainable materials contributes to the goal of improving environmental auditing.

Advances in battery technology for electric mobility: The Accelerated Cell and Battery Testing AccCellBaT project improves virtualization, front-loading, and continuous verification and validation (V&V) in order to optimize battery design, costs, and time to market.

Components made of zinc die-cast alloys are used in various industries due to their high surface and component quality and the efficiency of the hot-chamber die-casting process. However, they are rarely used for components subject to high cyclic loads because they lack structural durabiity characteristics. To change this, the cyclic material behavior of various zinc die-cast alloys was investigated and summarized in a design concept.

Cooling concept suitable for large-scale production: Innovative cooling design and materials enable lightweight energy storage devices with high capacity - Integrated winding head cooling based on duromers

Lithography is crucial for the manufacture of electronic semiconductors. New resists with high sensitivity and resolution are needed to increase component density and cope with mass production. With the IndiNaPoly project, Fraunhofer researchers aim to support the chemical industry in gaining a technological edge and tapping into new markets. Resist manufacturers are an important link in the semiconductor industry. Manufacturers of specialty polymers and semiconductors also benefit from the results.

Recycling is becoming increasingly important both socially and economically. In the field of plastics recycling, the recycling of polyolefin waste is becoming particularly important. However, insufficient information on the molecular structure and existing low-molecular impurities is a major obstacle, especially for upcycling. This can be ideally addressed by two-dimensional liquid chromatography, for which methods tailored to recycled materials must be developed. The Fraunhofer LBF is addressing this problem as part of the Industrial Collective Research project PORez.

Development of a sustainable, mobile and stationary energy storage system that is also designed to recycle the plastic.

Hydrogen performance center in Hesse

Fraunhofer researchers have developed a helmet with an integrated acceleration sensor for drivers of construction machinery. The helmet sensors measure the harmful vibrations from the construction machinery that affect the human body. The sensor signals are analyzed and software displays the level of exposure for the wearer. This allows measures to be taken to reduce exposure. A flexible piezo electret film serves as the sensor.

The icing of aircraft wings, especially on the leading edge, impairs aerodynamics and jeopardizes the safety and efficiency of flight operations. Conventional thermal de-icing systems are energy-intensive and incompatible with emission-free aircraft engines. In the EU project “UP-Wing” (Clean Aviation Innovation Program), Fraunhofer LBF is developing an innovative electromechanical de-icing system based on structural dynamic vibrations.

In the RE-IMPACT project, we have developed a non-destructive testing method based on the electromechanical impedance (EMI) method, which can be used to detect structural changes at an early stage and continuously monitor material quality.

Sustainable recycling management through artificial intelligence: Fraunhofer LBF is leading a work package in the K3I-Cycling innovation laboratory and is also contributing its many years of practical experience with plastic recyclates to other work packages.

The FutureCarProduction lead project focuses on the mobility lead market and develops solutions for sustainable and innovative car body concepts that go far beyond the current trend of giga-casting. Eight Fraunhofer Institutes are investigating the question of how production concepts for car bodies with state-of-the-art joining and casting technologies can be evaluated in terms of their effects on sustainability and recyclability in order to conserve resources and increase efficiency and performance. In the project, Fraunhofer LBF is answering the question of how the reliability and safety of modern car body structures can be assessed and verified.

Predictive maintenance and online monitoring in vehicle construction require precise characterization of the components to be monitored. Together with BMW, Fraunhofer LBF has developed a new methodology for simplified testing and characterization of structure-integrated high-voltage batteries. This involves testing a part of the car body with an integrated high-voltage battery on a multiaxial vibration table. Bearings with adjustable stiffness replicate the stiffness of the rest of the car body, enabling different scenarios to be tested quickly.

A technology platform is being developed to generate realistic rubber abrasion, which will be analyzed for material and tire development and used to forecast digitized driving analysis. This requires the development of a parametric friction surface and the generation of real reference particles. The degradation of the realistic abrasion produced is being investigated using new laboratory weathering techniques and chemical analyses. The results are being used for ecotoxicological assessments and also transferred to vehicle fleet simulations.

Passive hand prostheses with articulated fingers are often attractive to end users due to their low cost. The Fraunhofer Cluster of Excellence Programmable Materials (CPM) is developing a finger for a hand prosthesis that can assume four stable deformation states. The Fraunhofer LBF, IWM, ITWM, and IAP are collaborating on the “ProFi” project to replace the previous multi-part, screw-fastened solution with a single programmable metamaterial in order to reduce assembly costs. This has been achieved with a joint structure that has only one degree of rotational freedom and a small bending radius and is interconnected with bistable unit cells.

In the “FOLAMI” research project, Fraunhofer LBF focused on evaluating mixed steel and aluminum joints produced by form-fitting laser beam welding for durable semi-finished products in shipbuilding. Accompanying the welding process development, numerical and experimental investigations were carried out to verify the structural durabiity, initially at the sample level and then for specifically optimized adapters as connecting elements between steel and aluminum structural elements.

The ORka3D research project—optimization of resource use in welded structures through automated in-line service life assessment based on 3D scans—aims to develop an automated process for evaluating weld seam quality and the associated fatigue strength. This simplifies and improves quality control, as potential weak points can be identified and rectified immediately after production. The project aims to ensure consistent product quality while reducing costs.