Press releases 2017

The project “Technology for greater energy efficiency in distribution transformers” (FLUX-LMDR) was kicked off on 30  November 2017. Under the auspices of the Fraunhofer-Institut für Werkstoff- und Strahltechnik IWS Dresden, an alliance of five partners from science and industry will conduct research in laser processing of transformer sheets over the next three years. The application was approved by the Federal Ministry for Economy and Energy at the end of October. The Fraunhofer IWS will lead the technological development as well as take part in systems engineering.

On November 14th, 2017, the Fraunhofer focus project, futureAM, was launched in Aachen under the auspices of the Fraunhofer Institute for Laser Technology ILT. Six project partners – the Fraunhofer Institutes ILT, IWS, IWU, IGD and IFAM as well as the LZN Laser Zentrum Nord – have set themselves a clear goal: Over the next three years, they will work closely together to secure the prerequisites for significant technological leaps in additive manufacturing with metallic materials (metal AM).

At the Fraunhofer-Institut für Werkstoff- und Strahltechnik IWS, ten representatives of EU projects dealing with the subject "Thin, Organic and Large Area Electronics" (TOLAE) met for discussion. During the workshop, held from October 24 to 25, 2017, they presented their interim research results. The European Commission supports these projects as part of the Horizon 2020 program.

A higher laser beam cladding performance benefits Bosch Rexroth at the Dutch location Boxtel. The Fraunhofer-Institut für Werkstoff- und Strahltechnik IWS Dresden mutually optimized an industrial manufacturing process with the producer of drive and control engineering. For this purpose the IWS scientists upgraded an existing plasma powder welding machine. This way, large hydraulic cylinder rods can be coated considerably faster. Prof. Dr. Eckhard Beyer, managing director of Fraunhofer IWS, and Bernd Bodenstedt, Technical Plant Manager, Bosch Rexroth Boxtel, officially inaugurated the process.

Prof. Andrés Lasagni from the Institute of Manufacturing Engineering at the “Technische Universität Dresden” and head of the "Center for Advanced Micro-Photonics (CAMP)" at the Fraunhofer IWS received the Materials Science and Technology Prize 2017. Every two years the Federation of European Materials Societies (FEMS) awards the prize to young European materials scientists whose research work contributes significantly to material science and materials engineering.

The Fraunhofer IWS introduces two new coating solutions at the EMO Hannover 2017. The Dresden scientists present the diamond-like carbon coating “Diamor®” and a new concept for the fabrication of hard wear-protecting coatings with a thickness of more than 100 micrometers.

The Fraunhofer-Institut für Werkstoff- und Strahltechnik IWS developed the novel remote system concept (MuReA) for quick, flexible and efficient laser processing tasks. IWS scientists combined laser remote systems, spindle drives and high performance beam sources with each other. As a result, this novel laser system enables large-scale, flexible and quick processing tasks for materials such as aluminum, stainless steel as well as fiber reinforced polymers. Working areas of up to one square meter can be processed at a laser beam speed of up to 10 meters per second. In particular, the automotive and the aerospace industry will benefit from possible applications.

The hyperspectral imaging technology (HIS) perfectly meets the aspiration “to see more than the eye allows”. This novel camera technology enables to image light not only in a spatial but additionally in spectral resolution. To get dedicated sample information, it is now possible to analyze up to thousand spectral bands whereas formerly only three spectral bands (RGB) could be used. Fraunhofer IWS scientists have developed an integrated HSI solution, which implements the po-tential of the HSI technology into reliable hard- and software. The IWS technolo-gy is highly suitable for applications in the fields of surface and film inspection. Fraunhofer IWS will present the measuring system imanto® obsidian at the tradeshow LASER World of PHOTONICS in Munich.

Due to digitalized product development and cross-linked manufacturing cycles development periods have been radically shortened. Rapid product change requires from manufacturers and suppliers a high rate of flexibility, so that customized and cost-optimized solutions can be offered. For the development of new laser welding technologies individualized processes tailored for specific materials and products need to be combined with innovative hardware concepts. For the welding of difficult to weld materials a new high frequency beam oscillation welding head with integrated process monitoring – the remoweld®FLEX – has been developed, which is going to be presented at the industrial trade fair LASER World of PHOTONICS in Munich.

Functionalization of technical surfaces by means of natural, bio-inspired structures is an innovation driver of the 21th century. The functionalities achieved are applicable for e.g. improved bio-compatibility in medical and biotechnological industries, for tribological applications in the automotive industry and for optical applications such as product and brand protection. Fraunhofer IWS has been developing modularly designed solutions for surface functionalization tasks by fabricating micrometer and sub-micrometer structures in a targeted and flexible manner. Scientists of the Fraunhofer IWS will present for the very first time the worldwide most compact system for surface structuring by means of scanner-based direct laser interference patterning at the tradeshow Laser World of Photonics in Munich.

Confidence and reliability are key criteria for the potential introduction of innovative joining techniques. This is, in particular, also true for the modern maritime industry. Scientists of the Fraunhofer IWS have developed a novel, low heat-input but highly efficient laser welding technology for joining processes of up to 50 mm thick parts made of seawater-resistant aluminum alloys. A decisive advantage of this technology is the comparatively low laser power (< 4 kW) needed during the welding of thick metal sheets. The low laser power enables extraordinarily small weld seam widths and minimal component distortion. The IWS laser multi-pass-narrow-gap welding technology (laser MPNG) has been successfully certificated by the classification society DNV GL and is thus now ready for potential industrial applications.

Prof. Dr. Martina Zimmermann, head of the Fraunhofer IWS expert team “Materials Characterization and Testing” and holder of the professorship for “Mechanics of Materials and Damage Analysis”, TU Dresden, has been elected to be the new speaker of the German Materials Society (DGM) advisory board. The election took place within the framework of the first constituent meeting of the new advisory board at the Helmholtz-Zentrum Berlin für Materialien und Energie on March 16, 2017.

Scientists of the Fraunhofer IWS Dresden and the Fraunhofer IFAM Bremen have developed a novel technology for the large area, efficient and environmentally friendly pre-processing of fiber glass metal laminates (GLARE). This new technology has been jointly developed within the framework of the aeronautical research project » AUTOGLARE- advanced metal fuselage construction- fiber glass reinforced aluminum and automated manufacturing processes for high production rates in the aircraft industry; Sub-project NFM-GLARE «. The adhesively bonded multilayer composites, pre-processed by laser, verifiably provide excellent adhesion and corrosion properties so that chemical pre-processing in anodizing bathes are no longer necessary.

Integrated digitization of processes for laser materials processing provides customers with measurable results in industrial applications. Based on the IWS’ comprehensive systems engineering know-how, cyber-physical laser materials processing systems are being developed by means of new hardware and software solutions. These systems assist the operator in the performance of complex manufacturing tasks, they improve product quality, and they enhance the reproducibility of manufacturing results both for regular and frequently changing production sequences. Research developments for hardening, cutting and joining as well as for additive manufacturing processes will be presented at the Hannover Messe Industrie and at the Laser Messe München.

Lightweight design is one of the mostly progressive research areas involved in accomplishing the transition from fossil fuels to renewable energy sources, as well as the reduction of CO2 emissions. Innovative materials, such as carbon or glass fiber reinforced plastics (CFRP/GFRP), as well as metal foams, contribute to the successful implementation of the target set by the Federal Government. The Fraunhofer IWS has been researching in this field for many years to provide promising and affordable solutions for our industrial and research partners. One of these solutions is the laser-remote cutting technique.

Everyone wants medication – we’re not talking about animal testing here. Up to now, this has been a necessary evil in medical research. Microphysiological systems, in which organs and organ systems are “created” are a promising alternative. Therewith, complex mechanisms of the human body can be realistically analyzed. Among other things, these microsystems contain ducts, reservoirs, actuating elements, sensor technology and 3D scaffols “made by laser”. The Fraunhofer IWS offers partners from the fields of biology and medicine complete solutions for microsystem technology – from design to prototype, including the automation system.

Dresden researchers of the Fraunhofer IWS and the TU Dresden have developed a new energy-efficient process chain for carbon fiber manufacturing. The approach aims at the conversion of polyacrylonitrile (PAN) procurser fibers by means of their stabilization, carbonization and graphitization. Thereby, in future it will be possible to produce carbon fibers at clearly lower costs.

The Fraunhofer IWS Dresden and the Singapore Institute of Manufacturing Technology (SIMTech) have signed a memorandum of understanding for international collaboration in the fields of laser-based additive manufacturing and diamond-like hard coating technology.

The Fraunhofer IWS Dresden and Technische Universität Dresden inaugurated their jointly operated Center for Additive Manufacturing Dresden (AMCD) with a festive ceremony on February 7, 2017. Scientists from various disciplines perform research on materials, additive manufacturing processes and innovative technologies, which build up components in a layer by layer process. This technology opens up new horizons for component design and combinations of functions. For example during fabrication, electrical conductors and sensors are already able to be additively manufactured into components. They provide information about stress conditions of a product during operation.

The turn from traditional “monolythic” components, made of one single material, to hybride constructions made of atypical materials implies great challenges. Modern joining processes must be able to join most diversified materials in a robust and durable manner. The scientists of the IWS Dresden favour clamping structures for transition joints between metal, ceramics or plastic material. The tailored micro structures enable a later application of mechanically highly resistant joints between the parts to be connected.