Research and development focuses

Current projects | Completed projects

Nowadays, aluminum alloys are exceedingly used for modern constructional elements. Because of low density, aluminum alloys are up to standard of lightweight materials, without additional treatment, however, surface layer aluminum alloys are restrictedly applicable as high-performance material. Electron beam multi-processes provide a promising opportunity for generation of wear-resistant layers on aluminum structures.

• Wear and corrosion resistance of aluminum structures
• Reduction of the manufacturing expense by multi-process technologies
• Flexible processing by different technological processes at different effect places with only one electron beam

Contact: Dipl.-Ing. Andrea Rose

The project refers to investigations on the distortion occurred during the manufacturing of large aircraft structures. The complex manufacturing of these parts and the interaction of single processes in view of the final distortion, necessitate a system-oriented analysis of the whole process chain. The aim of the project is the minimization of the final distortion in order to reduce the effort for re-shaping of distorted parts prior to assembly. The project (T4) is part of the Transfer Research Centre 570 "Distortion Engineering - First implementations into industry" and founded by the Deutsche Forschungsgemeinschaft (DFG).  

• Determination of the distortion potentials during the manufacturing process of aluminum
• Analysis of the interactions of the measured parameters on the final product distortion
• Understanding of the distortion mechanisms in order to derive and implement compensation strategies for distortion reduction

Contact: Dr.-Ing. Kai Schimanski

Aluminum alloys with high Mg₂Si-content (22-35 wt.- %) offer the possibility of significant decrease in density and increase in stiffness even at elevated temperatures at the same time. This combination of properties is particularly important for automotive industries, e. g. in combustion engines. Because common casting processes would not lead to satisfying microstructures, these alloys were produced through spray forming. By injecting nano-scaled dispersoids an additional reinforcement of the aluminium matrix shall be achieved. After optimizing the spray forming process and investigating chemical compositions as well as age hardening, tailored alloys for industrial applications shall be produced.

• Advancement of the spray forming process for the production of new aluminum basis alloys
• Variation of the alloy composition and manufacturing parameter
• Analysis of the effects on microstructure and material properties

Contact: Dr.-Ing. Axel von Hehl

Today, aqueous quenching media are used predominantly for the quenching of age hardening aluminum alloys. This can lead to a non-uniform cooling of the parts. In relation to the conventional quenching procedures in aqueous media, gas quenching exhibits a number of advantages. The quenching rate can be adapted to the required material properties by varying gas type as well as gas pressure and gas flow velocity. Through higher uniformity and improved reproducibility of the heat treatment results, gas quenching offers a high potential to reduce scrap and rework costs.  

• Analysis and evaluation of interactions between heat treatment, material properties and distortion
• Determination of the capability of liquid and gaseous quenching media as well as different cooling methods
• Optimization of heat treatment techniques

Contact: Dipl.-Ing. Andrea Rose

Due to the request of weight and cost reduction, new innovative solutions for maximum utilization of materials are developed. The combination of different metallic materials is a forward-looking approach to further optimize lightweight structures. Typical material combinations to be joined by welding or extrusion are aluminium alloys with other aluminium alloys, titanium alloys or steels. The properties of the joints are not yet examined extensively. Developments of possible intermetallic phases in the interface as well as shaping of heat affected zones are investigated using light and electro microscopy. To figure out mechanical properties

• Function-optimized material development
• Examination under static as well as dynamic loads and evaluation of the failure behaviour
• Light and electron microscopic investigations

Contact: Dipl.-Ing. Ole Karsten