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© Fraunhofer IFAM W. Cavalcanti, B. Mayer Fraunhofer Institute IFAM Bremen, Germany Sept. 24, 2012 Adhesives Accelerating Innovation
36

Adhesives accelerating innovation.

May 19, 2015

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Palestra plenária do XI Encontro da SBPMat (Florianópolis, setembro de 2012). Palestrante: Bernd Mayer - IFAM/ Instituto Fraunhofer (Alemanha).
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Page 1: Adhesives accelerating innovation.

© Fraunhofer IFAM

1

W. Cavalcanti, B. Mayer

Fraunhofer Institute IFAM

Bremen, Germany

Sept. 24, 2012

Adhesives Accelerating Innovation

Page 2: Adhesives accelerating innovation.

© Fraunhofer IFAM

2

March 26, 1949: The Fraunhofer-Gesellschaft

is founded in Munich, Germany

1952: Fraunhofer-Gesellschaft is recognized

as 3rd pillar in the German research community

next to the Deutsche Forschungsgemein-

schaft (DFG) and the Max-Planck-Gesell-

schaft (MPG)

2012:

60 Fraunhofer-institutes

>21,000 employees, mainly with back-

ground in natural sciences or engineering

1,97 billion Euros1) annual research budget

The Fraunhofer-Gesellschaft

1) expected value

Page 3: Adhesives accelerating innovation.

© Fraunhofer IFAM

3

Joseph

von Fraunhofer

(1787-1826)

director and partner in

a glassworks

discovery of the

“Fraunhofer lines” in

the solar spectrum

new methods for

processing lenses

research volume

approx. 1.9 billion

Euros annually

research and

development on behalf

of industry and state

mp3 music format,

white LED, high-reso-

lution thermal camera

Researcher

Inventor

Entrepreneur

Fraunhofer

Gesellschaft

Page 4: Adhesives accelerating innovation.

© Fraunhofer IFAM

4

Fraunhofer-Gesellschaft promotes and under-

takes applied research in an international con-

text, of direct use to private and public enterprise

and of wide benefit to society.

By developing technological innovations and

novel systems solutions, Fraunhofer Institutes

support the competitive strength of the economy

in their region and beyond; with particular focus

on social welfare and environmental compatibility.

Fraunhofer-Gesellschaft enables its staff to de-

velop professional and personal skills to

assume positions of responsibility within their in-

stitute, in industry and in other scientific domains.

Mission of the Fraunhofer-Gesellschaft

Page 5: Adhesives accelerating innovation.

© Fraunhofer IFAM

5

7 Divisions:

Information and Communication Technology

Life Sciences

Microelectronics

Light & Surfaces

Production

Materials and Components - MATERIALS

Defense and Security

Profile of the Fraunhofer-Gesellschaft

7 Divisions:

Information and Communication Technology

Life Sciences

Microelectronics

Light & Surfaces

Production

Materials and Components - MATERIALS

Defense and Security

Page 6: Adhesives accelerating innovation.

© Fraunhofer IFAM

6

CORE COMPETENCIES

material development component and system reliability

technology development materials modeling and simulation

Fraunhofer Division “MATERIALS“

MATERIALS RESEARCH ACROSS ENTIRE VALUE CHAINS

from developing new materials through quasi-industrial scale manufac-

turing technology to the characterization of properties and assessment

of service behavior. Covering components their functions, as well

Page 7: Adhesives accelerating innovation.

© Fraunhofer IFAM

7

TECHNOLOGY

DEVELOPMENT

MATERIAL DEVELOPMENT

”smart“ materials and

components

(functional) polymers with

specific electrical, electro-

optical and optical properties

fibers and fiber composites,

advanced ceramics, nano-

materials, semiconductors,

phase change materials

active layers (photo catalysis,

electrically adjustable layers)

bio-based materials

coatings, surface modi-

fication, multi functional

materials

light metal casting, rapid

prototyping, microforming,

cellular materials

process technology

joining technologies and

machining procedures

testing technology

Fraunhofer Division “MATERIALS“

Page 8: Adhesives accelerating innovation.

© Fraunhofer IFAM

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MATERIALS MODELING

AND SIMULATION

COMPONENT AND

SYSTEM RELIABILITY

… of materials, components

and systems

… in terms of structural

durability, system reliability,

functionality

analysis, characterization

destructive and non-

destructive testing (NDT),

assessment

simulation technologies

multi-scale simulation

modeling and simulation

from elementary material

properties, materials

development and produc-

tion to service behavior of

components and systems

Fraunhofer Division “MATERIALS“

Page 9: Adhesives accelerating innovation.

© Fraunhofer IFAM

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Information and

Communication

Energy and Habitation generating, distributing and

use of electrical energy

Production and

Environment closed loop production

Health and Nutrition affordable health

Protection and Safety recognizing and control of

disasters

Mobility and Traffic low emission and reliable

mobility in urban areas

Global Objectives

Page 10: Adhesives accelerating innovation.

© Fraunhofer IFAM

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The Fraunhofer IFAM

Fraunhofer Institute for Manufacturing

Technology and Applied Materials

Research

established in 1968

headquarter in Bremen

sites in Dresden, Stade, Oldenburg

more than 500 employees;

research budget (2011) ca. 40 Mio. €

two divisions:

shaping and functional materials

adhesive bonding and surface

technology

close co-operation with local universities

Page 11: Adhesives accelerating innovation.

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Material Science at University of Bremen

“ambitious and agile“

“ambitioniert und agil“

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The “Technology Park Bremen“

Area 1,700,000 sqm Industry approx. 400 companies

(mainly SME) with 6,000 employees

University of Bremen more than 3,000 employees

and 20,000 students Research Institutes 20 institutes with more than

1,000 employees

Page 13: Adhesives accelerating innovation.

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GL - quality management certification acc. to ISO 9001

DAkkS - accredited testing laboratories acc. to ISO/IEC 17025

DAkkS - accredited employee qualification acc. to ISO/IEC 17024

NADCAP MTL/ NMMT – in progress

Certification / Accreditation

Page 14: Adhesives accelerating innovation.

© Fraunhofer IFAM

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technical systems focusing on interfaces

molecules - materials - manufacturing

technologies

Adhesive Bonding

Surface Technology and Coatings

Fiber Reinforced Plastics

material development

material characterization

application processes

structures

quality management

Adhesive Bonding and Surface Technology

Page 15: Adhesives accelerating innovation.

© Fraunhofer IFAM

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Surface Treatment

Process Engineering pilot-plant for plasma processes

paint application, drying

surface pretreatment

plasma processes and equipment

Material Screening / Qualification paint and coating accessories

raw material characterization

cleaning agents

Surface Analysis chemical, electrochemical and micro-

structural analyses

optical / mechanical properties, wetting

production-integrated quality assurance

failure analysis

Page 16: Adhesives accelerating innovation.

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Functional Surface Systems

erosion protection

corrosion protection drag reduction

wetting

LIG

HT W

EIG

HT M

AT

ER

IAL

S

Page 17: Adhesives accelerating innovation.

© Fraunhofer IFAM

17

Shark Skin for Transportation and Wind Energy

Nature as Model

Shark skin has a specific structure minimizing flow resistance. Challenge was to trans-

fer this knowledge to coatings passing extreme requirements of aerospace industry.

JOSEF-VON-FRAUNHOFER INNOVATION AWARD 2010 Yvonne Wilke, Dr. Volkmar Stenzel, Manfred Peschka

Page 18: Adhesives accelerating innovation.

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Riblet-type Structures

shaping and curing in a single stage

Page 19: Adhesives accelerating innovation.

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demand for economic

reproducing method of

surface topologies

moving direction

(1) shaping tool with negative micro-

structure at the outside

(2) UV-curing unit

(3) soft roller; flexibility adapted to the

curvature of the surface

(4) paint dosing unit

(5) guide roller

continuous application on large surfaces

Riblet-type Structures

solution: combined application

and embossing processes based

on UV-curable resins

Page 20: Adhesives accelerating innovation.

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corrosion

protection

hydrophobicity

hydrophilicity

protective coating

electronics

anti-adhesion coatings (demolding)

JOSEF-VON FRAUNHOFER INNOVATION AWARD 2012

Dr. Jörg Ihde, Dr. Uwe Lommatzsch

Page 21: Adhesives accelerating innovation.

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Release properties of

plasma coatings

de-molding of CFRP-

components

conventional release

coatings need rework

best release effect by

ND plasma coating

without rework

up to 40 de-molding

cycles proven

further optimization

ongoing

Example – Plasma Coatings for De-molding

Page 22: Adhesives accelerating innovation.

© Fraunhofer IFAM

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3D Deep-drawing Process, Vacuum-assisted

Page 23: Adhesives accelerating innovation.

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Example – FlexPLAS® Film Technology

Deep-drawable films for de-molding

plasma coatings avoiding adhesion of plastic parts to molds

No liquid release agents necessary

avoids cleaning stages

reduces cycle time and labor cost

minimizes VOC emissions

No release agents adhering to components

ready-to-paint surfaces; improved surface quality

positive effect on workers safety

Additional benefits

use film as protecting agent during transport or inspection

option to run in-mold paintings process

Page 24: Adhesives accelerating innovation.

© Fraunhofer IFAM

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Specialty Adhesives and Sealing

Develop / select formulations

Control substrate surfaces

validate methods for surface characterization

benefits in production, maintenance and

repair

Adhesive application

control geometry (position, volume) of

dispensed adhesives

mixing ratio of 2K adhesives

Bonded components

FEM simulation

non-destructive testing of bonded joints

structural health monitoring

Page 25: Adhesives accelerating innovation.

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Interphase: simulation of adhesion

mechanisms

Simulation and analysis of multi phase

adhesive systems

Simulating crash behavior of bonded structures

Design of bonded structures focusing on long

term durability at different conditions

(temperature, humidity, salt etc.)

Aging behavior:

assessment and route course analysis

Light weight design suitable

for adhesive bonding

Bonded Structures - Simulation and Modeling

Page 26: Adhesives accelerating innovation.

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customer- and

application-related

specifications fast

cure and

long shelf life

non-tacky

and good wetting

good adhesion

in uncured state

pre-applicable structural adhesives

Pre-applicable Structural Adhesives (“PASA”)

norms and

legal

requirements

Page 27: Adhesives accelerating innovation.

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induction heating

0 10 20 30 40 50 60 0

50

100

150

200

tem

pera

ture

[°C

]

time [s]

example: bonding bolts

pre-application of epoxy-based

reactive hotmelts

tack-free up to 50 C

induction heating

fast curing within seconds

integrated development of

adhesive formulations, warming

process and part geometry

development of application

process necessary

Pre-applicable Structural Adhesives PASA

Page 28: Adhesives accelerating innovation.

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I. PROTEIN BASED

ADHESIVES

II. BIO-FUNCTIONALIZED

SURFACES

III. BIO-COMPATIBLE

SURFACES

Interfaces between Biology/Chemistry and Materials

hybrid materials

sensorics bio active

bio stable

hybrid adhesives

marine adhesives

I. PROTEIN BASED

ADHESIVES

II. BIO-FUNCTIONALIZED

SURFACES

III. BIO-COMPATIBLE

SURFACES

Page 29: Adhesives accelerating innovation.

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Medical Engineering

blue mussel able to adhere to

low energy surfaces

glue is based on DOPA

containing peptides

synthesis of peptides containing

DOPA

formulating “conventional” ad-

hesives using such peptides as

components

such biomimetic hybrid adhe-

sives show promise for bonding

soft tissue

Biomimetic Medical Adhesives

Mytilus edulis

blue mussel shell

DOPA

dihydroxy-

phenylalanine

Page 30: Adhesives accelerating innovation.

© Fraunhofer IFAM

30 Prof. Dr. Bernd Mayer

Processes defining process windows

validation of machine and process capability

in-line process control, simulation

Products test methods, in-line if needed

non-destructive testing

structural health monitoring (SHM)

Norms international (minimum) standards

best practice benchmark

Personnel Training technology transfer

certified education

Focus Quality

Page 31: Adhesives accelerating innovation.

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31

ww

w.k

leben-in-b

rem

en.d

e

DVS®-EWF-European Adhesive Bonder - EAB

(DVS®-EWF-Klebpraktiker/in)

understand and realize work instructions

target group: skilled workers (operative level)

DVS®-EWF-European Adhesive Specialist - EAS

(DVS®-EWF-Klebfachkraft)

establish work instructions, guide workforce

target group: master and supervisor

DVS®-EWF-European Adhesive Engineer - EAE

(DVS®-EWF-Klebfachingenieur/in)

develop / implement adhesive bonding processes

target group: technical management level

Training Programs - Employee Qualification

Page 32: Adhesives accelerating innovation.

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Fiber Reinforced Plastic Materials

Contribution of Fraunhofer IFAM

matrix resins and fibers

material characterization and

manufacturing processes

surface preparation

joining techniques

coatings

non-destructive test methods

repair processes

employee qualification

Page 33: Adhesives accelerating innovation.

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joining techniques machining

components virtual CFRP-development

textile technologies light weight design

Innovation Works (IW)

application research (e.g. new resins)

CFRP Research Center Stade

Page 34: Adhesives accelerating innovation.

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Adhesive Bonding

Fully automated processing

One-step shim assembly

Fast curing adhesives / shims

Design flexible cell layout

Automated Assembly and Machining

Simultaneous machining

Failure preventing process

control

Automated drilling and milling

Preventing thermal damage and

delamination at cutting area

Page 35: Adhesives accelerating innovation.

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Automated Measurement and Positioning

Objectives

Enabling low cost standard robotics:

achieve higher precision

process parts with high geometri-

cal deviations

compensate part deformation

caused by process forces

Page 36: Adhesives accelerating innovation.

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Conclusion

MISSION: IMPOSSIBLE MISSION: POSSIBLE