MakeKryo II - Materialkennwertermittlung

Funded by: DLR Space Administration

Duration: 2021-2022

Mechanical Engineering (Prof. M. Sause)
 

Content:

Comprehensive and reliable determination of characteristic properties of fiber-reinforced composites at cryogenic temperatures has been possible only to a very limited extent so far. In a first project phase, test concepts and methods to determine compressive and shear properties of various fiber-reinforced composites at very low temperatures were already developed and validated. Based on this knowledge, this second project phase aimed to continue with the development of new test solutions to identify fracture mechanical parameters and to characterize bonded joints at very low temperatures.

Correlation between material microstructure and electromagnetic emission

Funded by: DFG Sachbeihilfe

Duration: 2020-2022

Mechanical Engineering (Prof. M. Sause)

Content:

This DFG project was concerned with the investigation of the fundamental relationships between the microstructure of materials and the generation of electromagnetic emission (EME) during the fracture process. EME is caused by the imbalance of charge carriers, due to the breaking of bonds and which is additionally set in motion by the dynamics of the fracture process. The influence of different parameters on the electromagnetic signals was investigated in more detail by series of measurements across material classes and then mapped in simulations. The understanding of the source mechanism was further extended and also the sensor technology was further developed in an application-oriented manner.

Manufacturing and characterization of interpenetrating metal-ceramic composites based on highly homogeneous foam structures

Content:

The project investigated a highly homogeneous ceramic foam and an interpenetrating metal-ceramic composite made from it by gas pressure infiltration.
The microstructure can be transferred by CT reconstruction into a model suitable for numerical simulation of the mechanical and thermal properties of both the ceramic foam and the interpenetrating composite. Methodological developments and the transfer of evaluation methods to metal-ceramic interpenetration composites exhibited novelty character in both the experimental and numerical areas of material characterization and led to a deeper understanding of the mechanisms of action in the material system.

SmartCut – Smart solutions for machining processes

Funded by: bayme vbm – KME Programm

Duration: 2021-2023

Mechanical Engineering (Prof. M. Sause)
 

Content:

Machining is a process step that is in many cases of central importance for product quality. Within the project machine and sensor data were used to increase tool life, reduce scrap and enable continuous quality monitoring of machining processes. For this purpose, modern machine learning methods were applied to real process data to demonstrate the concrete potential and to make the methods evaluable and available for companies.

Liquid metal infiltrated interpenetrating composites based on metallic glass - processing, characterization and modeling

Funded by: German Research Foundation (DFG)

Program: Individual Reasearch Grants

Duration: 01.07.2019 -  30.06.2023

Hybrid Composite Materials (Prof. K. Weidenmann)

Content:

In this project an interpenetrating metal matrix composite reinforced with a metallic glass (Ni₆₀Nb₂₀Ta₂₀) and a eutectic AlSi12-matrix was manufactured and characterized. Laser powder bed fusion was used to manufacture an open-porous lattice-like preform from amorphous powder. Subsequently, the preform was infiltrated with the AlSi12-matrix in a gas pressure infiltration process. In the process, the amorphous structure of the metallic glass was largely maintained. Due to the manufacturing process, the preform has an anisotropic structure which is reflected in the results of the structural, mechanical, and thermal characterization carried out. The results of the in-situ and ex-situ mechanical characterization show that the composite has a significantly higher compressive strength in the manufacturing direction than transversely to the manufacturing direction, and a different failure behavior was observed in both directions. TEM studies in correlation with the in-situ investigations show that good interfacial bonding has been achieved. Finally, the experimental results were validated with analytical models of thermal expansion and elastic properties and an FE model.

Additive manufacturing of temperature sensitive actuators

Content:

As part of the project, a manufacturing process for temperature-sensitive composite actuators consisting of a polymer matrix and wires made of a shape memory alloy was developed based on the Arburg plastic freeformer. Pre-stressed wires can be deposited during the printing process to produce actuators with high geometric complexity. The interface properties as well as the quasi-static and cyclic mechanical properties of the composite were characterised and modelled to map process-structure-property relationships. The focus was on the thermomechanical properties in order to determine the activation temperatures as a function of the preload as well as the forces that can be applied and on the optimisation of the polymer-wire interface. Following systematic material selection, adaptation of the surface pre-treatment of the wire and development of the printing process, a functional demonstrator in the form of a two-finger gripper was designed and manufactured.

WiR - Wissentransfer Region Augsburg - Digital Engineering and Automation

Funded by: BMBF – Innovative Hochschule – Exzellenzstrategie des Bundes

Duration: 2018-2023

Mechanical Engineering (Prof. M. Sause)
 

Content:

The project WiR dealt with the possibilities of designing knowledge transfer and the establishment of an innovation laboratory in the field of "Digital Engineering and Automation“. Robot-supported component testing was established in close cooperation with the Institute for Software and Systems Engineering. The aim was to enable mechanical testing of components using free force and moment vectors. For this purpose, a worldwide unique test bench was realized, comprising two 6-axis large payload industrial robots applying the loads to the component under test. Furthermore, relevant testing scenarios were outlined and secondary testing methods (e.g. Acoustic Emission Analysis, Digital Image Correlation) were developed further towards the requirements of component testing as well as different technical installations (e.g. CNC milling machine, 6-axis industrial robot, additive manufacturing) were equipped with a total of 24 different monitoring systems.

MAI CC4 HybCar – Technologien zur effizienten Herstellung von hybriden CFK/Metall-Strukturbauteilen im Automobilbereich

Funded by: Campus Carbon 4.0 – Neue Werkstoffe Bayern

Duration: 2017-2021

Mechanical Engineering (Prof. M. Sause)
 

Content:

For the use of fiber composites and CFRP-metal hybrids in the series production of automobiles, the automation of the production process is of very high importance. Within the scope of this project, work was therefore carried out on a new type of load-path-oriented material system and a suitable automated manufacturing process. It was focused on the characterization of the interface between metal and CFRP, as well as the forming behavior of the hybrid component.

MAI CC4 COSIMO – Composites for sustainable Mobility

Funded by: Campus Carbon 4.0 – Neue Werkstoffe Bayern

Duration: 2018-2021

Mechanical Engineering (Prof. M. Sause)
 

Content:

The goal of the project was the conceptual design and optimization of a T-RTM process to develop the basis for sustainable and efficient manufacturing processes in automotive and aircraft construction. For process monitoring and economic validation of the component quality, a sensor network of ultrasonic, pressure, temperature and dielectric sensors has been developed to be integrated in the T-RTM tool.
In designing the process monitoring, the focus was on evaluating the flow front dynamics and the degree of polymerization. Thus, the sensor network of ultrasonic sensors could be used to interpolate the propagation of the flow front and visualize it over the process time.

MAI CC4 FASTMOVE – Carbon-Hochgeschwindigkeits-5-Achssystem für die Bearbeitungsaufgaben der Zukunft

Funded by: Campus Carbon 4.0 – Neue Werkstoffe Bayern

Duration: 2017-2021

Mechanical Engineering (Prof. M. Sause)

Content:
As part of the project, a structural health monitoring system was developed for a 5-axis CNC milling machine. With this, the condition of the structural components of the milling machine could be monitored live by means of several acoustic measurement methods. In addition, the sharpness of the drill bit's cutting edges could be determined via structure-borne sound measurements and, at the same time, the machined component could be checked for defects.

MAI CC4 Hybrid – Hybrid composite laminates and joining technologies

Funded by: Campus Carbon 4.0 – Neue Werkstoffe Bayern

Duration: 2017-2021

Mechanical Engineering (Prof. M. Sause)

Content:

As part of the project, test methods for characterizing fiber-metal laminates were developed and brought together for in-situ tests. These resulting parameters made it possible to model the forming processes of the thermoplastic-based hybrid laminate semi-finished products.

MakeKryo – Material characterization at cryogenic temperatures

Funded by: DLR Space Administration

Duration: 2020-2021

Mechanical Engineering (Prof. M. Sause)

Content:

The aim of the project was to develop new testing solutions for the mechanical characterization of fiber composites under space conditions. Test devices were tested which can be used to determine compression and shear characteristics at temperatures down to 20 K. Valid results were obtained for various fiber composites.

Relation of electromagnetic and acoustic emission to temporal and spatial crack motion on a microscopic scale in polymers and carbon fibers

Funded by: DFG Sachbeihilfe

Duration: 2018-2021

Mechanical Engineering (Prof. M. Sause)
 

Content:

Within the framework of this project, the fundamental relationships of the formation of electromagnetic emission (EME) in polymers, reinforcing fibers and composites were investigated. At the same time, a measurement technique was established to record such EME in typical laboratory experiments and a theoretical model was developed to describe the EME source.

MAI ZfP - Combined non-destructive testing methods for quality assurance of fiber reinforced composites

Content:

Within the MAIzfp project, round robin tests of NDT methods were organised, automated test solutions further developed and the modelling of NDT methods more closely examined. Particular attention was paid to the investigation of porosity, fibre waviness and impact damage in fibre composites.
(BMBF, Leading-Edge Cluster MAI Carbon)

MAI Plast -  Development of cost-effective processing technologies for automated processing of high-performance thermoplastic composites for high-volume applications

Content:

Within the scope of the project the consolidation and deconsolidation as well as the forming behaviour of fibre-reinforced thermoplastics were investigated. For automated tape laying processes their implications were determined, and for PA-6 the influence of crystallinity on material properties was determined.
(BMBF, Leading-Edge Cluster MAI Carbon)

FORCIM³A - CFRP/metal composite research association for mechanical and plant engineering

Content:

Interfacial modifications of metal-CFK hybrid layered composites were investigated. The use of modern coating methods significantly increased adhesion and prevented contact corrosion.
(Bavarian Research Foundation)

ComBo - Efficient manufacturing technology for composite booster segments

Content:

Within the framework of the project, manufacturing technologies for future boosters of the ARIANE-6 program were investigated. The main focus was on the production with automated tape laying processes for thermoplastic CFRP tapes, as well as the monitoring of material development with test methods such as acoustic emission analysis.

(Bavarian Ministry of Economic Affairs, Regional Development and Energy)