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.
Metal foams are the ideal basic material for innovative lightweight design. Combining low weight and high stability, they have a high surface-to-volume ratio and absorb energy and sound almost ideally. They have already been used in various industrial applications, such as battery technology, heat exchangers and filter systems. Cost-efficient cutting of foamed material into parts with a defined shape has been the greatest technological challenge thus far.
Laser-remote cut fiberglass reinforced plastic and defined surface matrix ablation
© Fraunhofer IWS Dresden
The researchers at the Fraunhofer IWS have tackled this task with considerable success. They have achieved impressive results in terms of cutting velocity and quality in cutting open-porous metal foams to shape. »Enabling cutting velocities of up to 300 m/min in contour cutting and for material thicknesses of up to 20 mm, we are setting new stand-ards in metal foam processing« Robert Baumann, the head researcher, explains.
»The ±30 µm component tolerances achieved thereby are the best available worldwide; with them, it is possible to create intricate geometries with wall thicknesses of a few hundred micrometers« Baumann continues. At the Fraunhofer IWS, the research team is able to apply the latest laser beam sources of different wavelengths, power and beam quality, as well as commercial optical devices for processing.
The IWS‘ lightweight design know-how was enhanced through comprehensive R&D projects with regard to the cutting of non-metals and CFRP and FRP materials. Laser-remote cutting of composite materials makes it possible to combine the highly efficient cutting process with extremely high cutting edge quality.
The current focus is on the development of the automatable process to rework cutting edges of holes in fiber-reinforced plastics. A barrier layer is useful in carbon fiber reinforced plastics primarily to avoid corrosion in the joint with metals used in lightweight design and to prevent weathering due to environmental impacts.
»The results achieved with a prototype-tool are of outstanding quality« says Michael Rose, expert in laser-based cutting to shape of fiber-reinforced plastics at the IWS. »We are convinced that these results will be widely implemented in industry in the near future.«
The Fraunhofer IWS Dresden will present its latest technologies for processing new and composite materials with / without lasers at the this year’s Hannover Messe trade show. The digitalization of production engineering via materials sci-ence is a central focus. Visit us at our booth in Hall 6 / A30, as well as in the new »Industrial Supply Forum« to be held in Hall 5 on Monday, 24 April 2017.
For additional information, please contact:
Fraunhofer-Institut für Werkstoff- und Strahltechnik IWS Dresden
01277 Dresden, Winterbergstr. 28, Germany
Phone: +49 351 83391-3423
Fax: +49 351 83391-3300
Phone: +49 351 83391-3539
Fax: +49 351 83391-3300
Dr. Ralf Jäckel
Phone: +49 351 83391-3444
Fax: +49 351 83391-3300
To keep pace with the pulse of research anytime, follow us at:
YouTube: Fraunhofer IWS
Dr. Ralf Jaeckel | Fraunhofer-Institut für Werkstoff- und Strahltechnik IWS
AchemAsia 2019 will take place in Shanghai
15.06.2018 | DECHEMA Gesellschaft für Chemische Technik und Biotechnologie e.V.
Insects supply chitin as a raw material for the textile industry
05.06.2018 | Fraunhofer-Institut für Grenzflächen- und Bioverfahrenstechnik IGB
A new manufacturing technique uses a process similar to newspaper printing to form smoother and more flexible metals for making ultrafast electronic devices.
The low-cost process, developed by Purdue University researchers, combines tools already used in industry for manufacturing metals on a large scale, but uses...
For the first time ever, scientists have determined the cosmic origin of highest-energy neutrinos. A research group led by IceCube scientist Elisa Resconi, spokesperson of the Collaborative Research Center SFB1258 at the Technical University of Munich (TUM), provides an important piece of evidence that the particles detected by the IceCube neutrino telescope at the South Pole originate from a galaxy four billion light-years away from Earth.
To rule out other origins with certainty, the team led by neutrino physicist Elisa Resconi from the Technical University of Munich and multi-wavelength...
For the first time a team of researchers have discovered two different phases of magnetic skyrmions in a single material. Physicists of the Technical Universities of Munich and Dresden and the University of Cologne can now better study and understand the properties of these magnetic structures, which are important for both basic research and applications.
Whirlpools are an everyday experience in a bath tub: When the water is drained a circular vortex is formed. Typically, such whirls are rather stable. Similar...
Physicists working with Roland Wester at the University of Innsbruck have investigated if and how chemical reactions can be influenced by targeted vibrational excitation of the reactants. They were able to demonstrate that excitation with a laser beam does not affect the efficiency of a chemical exchange reaction and that the excited molecular group acts only as a spectator in the reaction.
A frequently used reaction in organic chemistry is nucleophilic substitution. It plays, for example, an important role in in the synthesis of new chemical...
Optical spectroscopy allows investigating the energy structure and dynamic properties of complex quantum systems. Researchers from the University of Würzburg present two new approaches of coherent two-dimensional spectroscopy.
"Put an excitation into the system and observe how it evolves." According to physicist Professor Tobias Brixner, this is the credo of optical spectroscopy....
13.07.2018 | Event News
12.07.2018 | Event News
03.07.2018 | Event News
20.07.2018 | Power and Electrical Engineering
20.07.2018 | Information Technology
20.07.2018 | Materials Sciences