© Fraunhofer IFAM W. Cavalcanti, B. Mayer Fraunhofer Institute IFAM Bremen, Germany Sept. 24, 2012 Adhesives Accelerating Innovation
May 19, 2015
© Fraunhofer IFAM
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W. Cavalcanti, B. Mayer
Fraunhofer Institute IFAM
Bremen, Germany
Sept. 24, 2012
Adhesives Accelerating Innovation
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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
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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
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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
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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
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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
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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“
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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“
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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
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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
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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
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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
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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
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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
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Functional Surface Systems
erosion protection
corrosion protection drag reduction
wetting
LIG
HT W
EIG
HT M
AT
ER
IAL
S
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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
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Riblet-type Structures
shaping and curing in a single stage
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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
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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
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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
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3D Deep-drawing Process, Vacuum-assisted
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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Conclusion
MISSION: IMPOSSIBLE MISSION: POSSIBLE