Forum for Science, Industry and Business

Sponsored by:     3M 
Search our Site:

 

For EVs with higher range: Take greater advantage of the potential offered by lightweight construction materials

21.10.2019

Ultra-high-strength aluminium alloys are the future of lightweight construction in conventional and e-mobility. Fraunhofer Institute for Structural Durability and System Reliability LBF is developing resource-optimized process technologies within the framework of ALLEGRO, the central project of LOEWE – Landes-Offensive zur Entwicklung Wissenschaftlich-ökonomischer Exzellenz (State Offensive for the Development of Scientifically Economic Excellence), with which local component properties can be adjusted to meet future requirements. The scientists evaluate the entire process chain in order to optimize it economically and ecologically and to enable a more sustainable product design.

The expansion of electro-mobility requires electric cars to have longer ranges. Lightweight materials with optimized material properties can help put this into practice. The key to this lies in the combination of ultra-high-strength aluminium alloys and new forming processes so that local component properties can be adjusted as required.


New, fine-resolution testing system for determining the local, process-related influencing parameters on the cyclic material behavior.

Foto: Fraunhofer LBF, Raapke

In order to make optimum use of the lightweight construction potential of aluminium alloys, the geometric and microstructural complexity of products must be increased.

Structural durability plays a central role here. Previous evaluation concepts, however, can only reproduce local material properties to a limited extent due to the manufacturing process.

The Fraunhofer LBF is developing new evaluation concepts for process-related structural durability within the framework of the central LOEWE project, ALLEGRO, taking into account the cyclical transient material behavior, in order to be able to increase the lightweight construction potential of the new manufacturing processes.

»With these more precise assessments, improvements can be achieved in the fatigue life approach of components according to the material. They are an important prerequisite for the industrial application of the new technologies and enable a more sustainable product design in lightweight construction,« explains Maciolek, a researcher at Fraunhofer LBF.

Materials examined down to the smallest Detail

As part of ALLEGRO, the Darmstadt-based scientists are specifically trying to use process-related properties of ultra-high-strength aluminium alloys to improve the service life of components.

For this purpose, the Institute for Production Technology and Forming Machines at the Technical University of Darmstadt and the Department for Separating and Joining Manufacturing Processes at the University of Kassel are developing manufacturing technologies as part of LOEWE's ALLEGRO project in order to implement both ecologically and economically efficient forming processes with integrated heat treatment.

In future, these processes will be used to produce semi-finished products with locally adapted properties that have been calibrated to suit the function and loads of the application in question.

The scientists at Fraunhofer LBF are investigating the entire process chain in order to be able to take advantage of the local process-related properties in terms of lightweight construction using the example of an e-bike frame.

The microstructure and the material properties are influenced by various process steps along this chain, which in turn determine the component behavior. If these local material properties can be determined and taken into account in the design and evaluation of cyclically stressed components and structures, then the potential in lightweight construction can be exploited in a targeted manner.

Since components are usually composed of several semi-finished products, the scientists must also investigate the joinability of the graded semi-finished products. The challenge when it comes to joining is to maintain the property gradation of the semi-finished product or even to introduce it by joining. Suitable joining processes are laser beam welding, friction stir welding and magnetic pulse welding, which will be investigated in more detail in the project.

On November 7, 2019 Andreas Maciolek will give a lecture entitled »Cyclic material behavior of aluminum wrought alloys considering heat treatment and prestrain« at the LightMAT conference in Manchester with current results of the Fraunhofer LBF from ALLEGRO.

Sponsors and partners of the ALLEGRO project are the LOEWE Landes Offensive zur Entwicklung Wissenschaftlich-ökonomischer Exzellenz, the federal state of Hessen, as well as the University of Kassel and the Technical University of Darmstadt.

Wissenschaftliche Ansprechpartner:

M.Sc. Andreas Maciolek, andreas.maciolek@lbf.fraunhofer.de

Originalpublikation:

www.lbf-jahresbericht.de/en/services/project-overview/lightweighting/allegro-high-performance-aluminum-alloy-components/

Anke Zeidler-Finsel | Fraunhofer-Institut für Betriebsfestigkeit und Systemzuverlässigkeit LBF
Further information:
http://www.lbf.fraunhofer.de

More articles from Materials Sciences:

nachricht Freiburg researcher investigate the origins of surface texture
17.02.2020 | Albert-Ludwigs-Universität Freiburg im Breisgau

nachricht Understanding Metal Ion Release from Hip Implants
17.02.2020 | Max-Planck-Institut für Eisenforschung GmbH

All articles from Materials Sciences >>>

The most recent press releases about innovation >>>

Die letzten 5 Focus-News des innovations-reports im Überblick:

Im Focus: Freiburg researcher investigate the origins of surface texture

Most natural and artificial surfaces are rough: metals and even glasses that appear smooth to the naked eye can look like jagged mountain ranges under the microscope. There is currently no uniform theory about the origin of this roughness despite it being observed on all scales, from the atomic to the tectonic. Scientists suspect that the rough surface is formed by irreversible plastic deformation that occurs in many processes of mechanical machining of components such as milling.

Prof. Dr. Lars Pastewka from the Simulation group at the Department of Microsystems Engineering at the University of Freiburg and his team have simulated such...

Im Focus: Skyrmions like it hot: Spin structures are controllable even at high temperatures

Investigation of the temperature dependence of the skyrmion Hall effect reveals further insights into possible new data storage devices

The joint research project of Johannes Gutenberg University Mainz (JGU) and the Massachusetts Institute of Technology (MIT) that had previously demonstrated...

Im Focus: Making the internet more energy efficient through systemic optimization

Researchers at Chalmers University of Technology, Sweden, recently completed a 5-year research project looking at how to make fibre optic communications systems more energy efficient. Among their proposals are smart, error-correcting data chip circuits, which they refined to be 10 times less energy consumptive. The project has yielded several scientific articles, in publications including Nature Communications.

Streaming films and music, scrolling through social media, and using cloud-based storage services are everyday activities now.

Im Focus: New synthesis methods enhance 3D chemical space for drug discovery

After helping develop a new approach for organic synthesis -- carbon-hydrogen functionalization -- scientists at Emory University are now showing how this approach may apply to drug discovery. Nature Catalysis published their most recent work -- a streamlined process for making a three-dimensional scaffold of keen interest to the pharmaceutical industry.

"Our tools open up whole new chemical space for potential drug targets," says Huw Davies, Emory professor of organic chemistry and senior author of the paper.

Im Focus: Quantum fluctuations sustain the record superconductor

Superconductivity approaching room temperature may be possible in hydrogen-rich compounds at much lower pressures than previously expected

Reaching room-temperature superconductivity is one of the biggest dreams in physics. Its discovery would bring a technological revolution by providing...

All Focus news of the innovation-report >>>

Anzeige

Anzeige

VideoLinks
Industry & Economy
Event News

70th Lindau Nobel Laureate Meeting: Around 70 Laureates set to meet with young scientists from approx. 100 countries

12.02.2020 | Event News

11th Advanced Battery Power Conference, March 24-25, 2020 in Münster/Germany

16.01.2020 | Event News

Laser Colloquium Hydrogen LKH2: fast and reliable fuel cell manufacturing

15.01.2020 | Event News

 
Latest News

First research results on the "spectacular meteorite fall" of Flensburg

18.02.2020 | Earth Sciences

Blood and sweat: Wearable medical sensors will get major sensitivity boost

18.02.2020 | Life Sciences

How to mend a broken heart

18.02.2020 | Life Sciences

VideoLinks
Science & Research
Overview of more VideoLinks >>>