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Influence of the ratio of rotational direction and speed at FSW tool on fatigue strength of Al alloys – FSW-Fatigue

Duration: 2017 until 2019 Project partner: Ilmenauer Fertigungstechnik Sponsor: Federal Ministry for Economic Affairs and Energy

The aim of the project lies in the adjustment of both material flow and heat input in friction stir welding, in order to improve the fatigue behavior and reduce the related forces and loads on clamping devices. This is to be achieved by decoupling the pin and shoulder movement during welding treatment. The underlying approach is that the heat input can be influenced by distinct settings of rotational speed and direction between the pin and shoulder, thus significantly affecting the material flow. Furthermore, the grain size and its distribution are witnessed to vary in the stirred and thermo-mechanically affected zone. A uniform grain distribution is to be assumed in special cases, for the existence of different conditions for crack initiation and fatigue failure.

For further information, please refer to:
M.Sc. Abootorab Chehreh



Investigations on the influences of surface topography and corrosion on the fatigue strength of steel/aluminum hybrid sheets produced by magnetic pulse welding – SchwingStAl-K.O.

Duration: 2017 until 2019 Project partner: tff Sponsor: BMWi_en_2
SchwingStAl-K.O.1 SchwingStAl-K.O.2

Magnetic pulse technology allows welding of hybrid components of steel and aluminum with low amount of thermal distortion and without temperature-induced microstructural changes. The aim of the project is the efficient characterization of the fatigue behavior and damage mechanisms of steel/aluminum-joints produced by magnetic pulse welding, which have not yet been properly researched, by means of combined load increase and constant amplitude testing procedure. The focus of the investigations is the determination of the influences of specifically adapted surface topographies and corrosion on the fatigue strength and damage propagation.

For further information, please refer to:
M.Sc. Selim Mrzljak



Analysis and extension of the limits of application in metal forming based recycling of aluminum chips

Duration: 2016 until 2019 Project partner: Institut für Spanende Fertigung Sponsor: Deutsche Forschungsgesellschaft (DFG)
AlSpaene1 AlSpaene2
Source: IUL

The direct extrusion of aluminium scrap materials offers a significant improvement for the life cycle of aluminium based materials in contrast to conventional remelting. Based on previous research in the area of compression of different chip shapes, the focus is placed on the relationships between process parameters and material characteristics in terms of qualitative and quantitative description of material and component properties. The opportunities of the process should be developed and the produced material characteristics should be evaluated regarding fatigue, lifetime and corrosion. The aluminum alloy EN AW-6060 is used as specimen material in this project.



Microstructure- and mechanism-correlated characterization of the corrosion fatigue behaviour of the creep-resistant magnesium alloys DieMag422 and AE42

Duration: 2014 until 2018     Sponsor: Deutsche Forschungsgesellschaft (DFG)

Magnesium alloys provide a great lightweight design potential, based on their good specific strength. The use in lightweight design applications is limited due to their low corrosion resistance, which affects fatigue strength negatively. In this project, magnesium alloys are investigated experimentally under superimposed corrosive and cyclic loading, in order of model-based description of interaction between corrosion and fatigue behaviour. The focus are heat-resisting magnesium alloys for automotive engineering, whose potential application area involves corrosion fatigue loading.



Fatigue life investigations of laser-additive-manufactured aluminum alloys

Duration: 2013 until 2018 Project partner: IAPT   

Knowledge about the fatigue performance of a material is mandatory before the component can be employed in cyclically loaded applications. Selective laser melting (SLM) is a relatively new additive manufacturing process having competitive advantages in case of complex geometries and customized parts. The light-weight material aluminum is sought for automobile and aerospace applications. The goal of this project is to investigate the feasibility of utilizing SLM process for dynamic applications. The effect of SLM parameters on mechanical performance of parts will be studied, experimental determination of fatigue performance of SLM parts would be carried out, and a concept for improving their fatigue performance would be developed.



Novel test systematics for the characterization of corrosion-fatigue-behaviour of brazing joints

Duration: 2015 until 2018 Project partner: Lehrstuhl für Werkstofftechnologie Sponsor: Deutsche Fördergebergesellschaft (DFG)

The characterization of the fatigue behaviour and the determination of the lifetime of brazed joints especially under superimposed corrosive loading are of central importance for many industrial applications and a fundamental requirement for the reliable and economic operation of brazed components. In this research project for 1.4301/Ni 620 and 1.4301/Au 827 joints novel testing methods are applied to obtain detailed knowledge of the fatigue and lifetime behaviour with a significantly reduced number of specimens.



Development of a lifetime monitoring for a lightweight hybrid screening machine for the energy-efficient use in high-frequency range

Duration: 2016 until 2018 Project partner: Lehrstuhl für Werkstofftechnologie Sponsor: BMWi
HFIM-Bilder Siebdruckmaschine

Considering their light weight combined with excellent mechanical properties, composites provide a high potential in lightweight construction. To use this potential has long been reserved by aerospace industry, based on economic reasons. Declining costs ensure that composites could use for other applications e.g. screening machines. In this ZIM-project new joints between composites and conventional materials are conceived with subsequent model-based description of fatigue behavior. The aim on the one hand is to produce a lighter and therefore more efficient screening machine and on the other hand to create hybrid joints which are subjected to constant vibration stress and nevertheless feature high fatigue strength.



Application of laser additive manufacturing for development of high strength aluminium alloy (EN AW-7075) for aerospace application – ALOHA

Duration: 2015 until 2017 Consortium: 2 Universities
3 Industrial Enterprises
Sponsor: Bundesministerium für Wirtschaft und Energie (BMWi)
Aloha1 ALOHA

Topography-optimized, light-weight and resource-efficient components are required by aerospace industry which usually make the component too complex to be manufactured by conventional processes. Additive manufacturing process offers the solution to build complex and customized parts using powder material. At the same time, it is required to manufacture components which are defect-free. Currently there is no high-strength aluminium alloy being processed by additive manufacturing. Therefore the goal of the project is the development of additive manufacturing process for quality assured high strength aluminium alloy EN AW-7075. The aim is to develop an efficient test methodology (RAPID-SLM) to reliably predict the fatigue life of additive manufactured components. It will take into account the influence of process-induced defects and their distribution on the resulting fatigue life and will propose process-optimization accordingly.



Injection Molding of Polyurethane Resin for impact-resistant structural composite parts – PRISCA

Duration: 2014 until 2017 Consortium: 3 Universities
6 Industrial Enterprises
Sponsor: Bundesministerium für Wirtschaft und Energie (BMWi)
Prisca Prisca

Parts out of composites need to demonstrate high impact toughness and halogen-free fire protection for application in aeronautical structures. Within this EU-cooperation-project PRISCA, materials and methods are developed to produce polyurethane components with resin transfer molding (RTM). The main objectives are increased impact toughness and the implementation of a manufacturing process for medium length production runs of monolithic and sandwich structures. To optimize the manufacturing process, a short-time testing methodology is going to be developed at WPT, to enable a resource-efficient assessment of the influence of the manufacturing parameters on the fatigue behaviour.




Non-destructive in-situ monitoring for the optimization of coating microstructure in plasma-, arc- and HVOF-based thermal spray processes – OptiMorph

Duration: 2015 until 2017 Project partner: Lehrstuhl für Werkstofftechnik Sponsor: Bundesministerium für Wirtschaft und Energie (BMWi)
Thermisches Spritzen Spritzschicht

The research project comprises the utilization of the innovative concept of high-frequency impulse measurement (HFIM) in combination with magnetic Barkhausen noise analysis (BNA) for the detection, evaluation and quantification of inhomogeneities in thermal spray coatings. The project aims at an integrated solution for reliable and fast inspection of thermal-spray-processes and -coatings by means of a pattern recognition algorithm for both high-frequency impulse measurement and Barkhausen noise analysis. Such a combination of the two measurement principles has the potential for substituting conventional optical methods for process control in thermal spraying and for a reduction of the need for costly metallographic analysis. The cost-effective measurement strategy enables small and medium-sized enterprises (SME) to conduct a non-destructive 100%-inspection of their coatings for the benefit of a high-quality portfolio and hence an increased market share.



Evaluation and modeling of the performance of fasteners made of hardwood with reinforced glued rods of steel and composite materials – TACITUS

Duration: 2015 until 2017 Consortium: 2 Universities
1 Fraunhofer-Institute
Sponsor: Bundesministerium für Wirtschaft und Energie (BMWi)
Tacitus Tacitus Tacitus

            Source: TimberTower

In timber engineering reinforced glued steel rods are successfully used as a fastener for many years. This approach of joining technology is suitable for power transmission, amplification and additional safety in connections and fitting edges and has many advantages over mechanical fasteners. In particular, standardized, firmly bonded, rigid, ductile and aesthetic node connections can be implemented, which leads to very economic structures. New technical territory is entered by bonding rods of steel and glass fiber reinforced plastics (GRP) in hardwoods. The fundamental insights of these components are still missing on suitable adhesives to the behavior of the entire system of rod, adhesive and hardwood under quasi-static and cyclic loads as well as suitable methods of dimensioning.



Combination of acoustical, electrical and magnetical measuring methods for precise in-line monitoring and quality control of metal-working processes – AEM-Process

Duration: 2014 until 2016 Project partner: QASS GmbH Sponsor: Bundesministerium für Wirtschaft und Energie (BMWi)

Within the scope of this project it is planned to develop a sensor system for industrial application, which comprises three different non-destructive testing methods. The objective is to design an integrative sensor system for rapid and precise process and quality control of metal-working processes by combining acoustical emission measurement, alternating current potential drop method and Barkhausen-noise analysis.



Multi Mega Watt from Offshore Wind Energy – MOEWE

Duration: 2011 until 2015 Consortium: 2 Universities
3 Industrial Enterprises
5 Subcontractors
Sponsor: Bundesministerium für Wirtschaft und Energie (BMWi)

The aim of the project “MOEWE” is the identification of damage relevant incidents, with the aid of multi-body simulations of the whole power train. These results will be determined in bench tests. By identifying the damage relevant incidents, it will be possible to develop new materials and surface coatings in combination with adjusted lubricant concepts. These results will be validated in fundamental- and component-testing as well as an application in wind power plants. A condition-monitoring-system for online surveillance is developed and calibrated simultaneously, during the evolution and validation of new materials. On the basis of these sensors, the damage condition is intended to be recorded in a non-destructive way, thereby resulting in the capability of early damage detection.