Projects
Current projects
In the following you will find a short overview of our current research projects.
ODIN
ODIN – Optimized Design for Inspection
Founded by: European Union
Program: COST Action 18203
Duration: 02.10.2019 - 01.10.2023
Mechanical Engineering (Prof. M. Sause)
Content:
Within the EU-COST network we provide the representation of the Federal Republic of Germany and the lead of WP5 - Data management and signal processing. The goal of this expert network is to develop the technical standards for the use of structural monitoring systems (SHM) for aviation applications within the next four years. Within WG5, the work focuses on analysis strategies, data reduction methods and reliability of the measurement systems used.
Interpenetrating metallic-glass-composites
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:
The aim of the project is the investigation of MMCs with a 3-dimensional interpenetration structure of metallic glass. A good reinforcing effect can be achieved by successfully embedding metallic glass into a metallic matrix. Especially under compressive loads higher mechanical properties can be expected, because the collapse of the foam webs leads to higher plasticity. The metallic glass foam processing planned in the present application is realized by means of die hot pressing. The open-pore metallic glass foam produced in this way is infiltrated by means of gas pressure infiltration with aluminum afterwards. Finally, the process-structure-property relationships will be investigated. The methods used include 2- and 3-dimensional microstructure analysis, determination of the elastic properties by means of ultrasonic phase spectroscopy, mechanical tests with (in-situ) and without (ex-situ) simultaneous analysis of the damage behavior, determination of the thermal expansion coefficient, and the influence of thermal-mechanical loads on the structure and properties of the composite.
Interpenetrating Metal-Ceramic-Composites
Manufacturing and characterization of interpenetrating Metal-Ceramic-Composites based on highly homogeneous foam structures
Founded by: German research foundation (DFG)
Program: Individual Research Grants
Duration: 01.06.2019 - 31.05.2023
Hybrid Composite Materials (Prof. K. Weidenmann)
Content:
The research project deals with the manufacturing, characterization, and in a partner project of the Institute for Applied Materials Computational Materials Science (IAM-CMS) at the Karlsruhe Institute of Technology (KIT) with the modeling of interpenetrating composites based on highly homogeneous ceramic foam structures. The innovative foam manufacturing process, used in this project, is derived from the field of high-temperature thermal insulation. It allows for the first time to produce novel ceramic foams with a highly homogeneous structure and high porosity fractions in a process-safe and resource-efficient way without the use of pore-forming fillers. The research project deals holistically with these novel penetration materials and aims to analyze and document the damage behavior in all load cases by in-situ and ex-situ investigations in order to obtain an exact understanding of the damage mechanisms and the damage process in the composite.
SmartCut
SmartCut – Smart solutions for machining processes
Founded by: KME - Kompetenzzentrum Mittelstand GmbH
Duration: 01.05.2021 – 30.04.2023
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 are used to increase tool life, reduce scrap and enable continuous quality monitoring of machining processes. For this purpose, modern machine learning methods will be applied to real process data to demonstrate the concrete potential and to make the methods evaluable and available for companies.
Additive manufacturing of temperature sensitive actuators
Additive manufacturing of temperature sensitive actuators manufactured from NiTi shape memory wires embedded in polymer structures
Founded by: German research foundation (DFG)
Program: Individual Research Grants
Duration: 01.10.2019 - 31.03.2023
Hybrid Composite Materials (Prof. K. Weidenmann)
Content:
Temperature sensitive actuators made from shape memory alloys integrated in polymer matrices offer an alternative to conventional electronic actuators due to their simple design and high specific energy. Shape memory alloys (SMA) in the form of wires are embedded in a thermoplastic polymer matrix by a modern additive manufacturing process and thus allow a high functional integration potential of the composite actuators.
In order to produce actuators from a polymer and shape memory wire composite, a suitable material combination must be found first. In this case, the properties must be complement to each other in such a way that an optimal actuator function is given. In addition, the interface must be optimized for mechanical stress, since this represents the interface between the materials and is decisive for the performance of the actuator.
Finally, the functionality of the actuator as well as the fatigue behaviour of the composite must be investigated to ensure long-term actuator function.
WiR Augsburg
WiR - Wissentransfer Region Augsburg - Digital Engineering and Automation
Funded by: Federal Ministry of Education and Redearch
Program: Innovative Hochschule
Duration: 01.01.2018 31.12.2022
Mechanical Engineering (Prof. M. Sause)
Contents:
The project WiR deals with the possibilities of designing knowledge transfer and the establishment of an innovation laboratory in the field of "Digital Engineering and Automation“. Within subproject 1.1, robot-supported component testing is established in close cooperation with the Institute for Software and Systems Engineering. The aim is to enable mechanical testing of components using free force and moment vectors. For this purpose, a worldwide unique test bench will be realized, comprising two 6-axis large payload industrial robots applying the loads to the component under test. Furthermore, relevant testing scenarios are outlined and secondary testing methods (e.g. Acoustic Emission Analysis, Digital Image Correlation) are developed further towards the requirements of component testing. Within subproject 1.3, different technical installations (e.g. CNC milling machine,
6-axis industrial robot, additive manufacturing) will be equipped with a total of 24 different monitoring systems. On the one hand this provides a platform for testing and evaluation of the different concepts in context of the chosen application scenarios, on the other hand it serves as an environment for the development of techniques concerning the data fusion of the various measurement techniques.
MakeKryo II
MakeKryo II - Determination of material properties at cryogenic temperatures
Funded by: German Aerospace center (DLR)
Program: National Space Program
Duration: 01.06.2021 – 31.07.2022
Mechanical Engineering (Prof. M. Sause)
Contents:
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 aims to continue with the development of new test solutions to identify fracture mechanical parameters and to characterize bonded joints at very low temperatures.
Electromagnetic Emission
Correlation between material microstructure and electromagnetic emission
Funded by: German Research Foundation (DFG)
Program: Individual Research Grants
Duration: 01.03.2018 - 30.06.2022
Mechanical Engineering (Prof. M. Sause)
Content:
This DFG project is 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 is to be investigated in more detail by series of measurements across material classes and then mapped in simulations. The aim is to further extend the understanding of the source mechanism and at the same time to further develop the sensor technology used in an application-oriented manner.
Completed research projects
In the past, various projects were carried out together with research and application partners. The gallery presents an overview of the projects.
MAI CC4 COSIMO
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 HybCar (videolink)
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 FASTMOVE
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. (Campus Carbon 4.0 - New Materials in Bavaria).
MAI CC4 Hybrid – Hybrid composite laminates and joining technologies
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. (Campus Carbon 4.0 - New Materials in Bavaria)
MakeKryo – Material characterization at cryogenic temperatures
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. (DLR Space Administration)
Relation of electromagnetic and acoustic emission to temporal and spatial crack motion on a microscopic scale in polymers and carbon fibers
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. (DFG)
MAI ZfP - Combined non-destructive testing methods for quality assurance of fiber reinforced composites
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
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)
CFRP/metal composite research association for mechanical and plant engineering - FORCIM³A
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
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)