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Increasing demands on sheet metal forming processes require ever more extensive experimental characterizations of the original base materials. At the same time, the characterization tests used are constantly facing new challenges due to the use of thinner sheets of metal. The Virtual Lab of the Fraunhofer Institute for Mechanics of Materials IWM in Freiburg provides a remedy for this: It determines the necessary characteristic values for the design of sheet metal forming processes via simulation. The Fraunhofer IWM is cooperating with the University of Twente in the Netherlands to further develop the Virtual Lab.

Programmable materials are true shapeshifters. They can change their characteristics in a controlled and reversible way with the push of a button, independently adapting to fit new conditions. They can be used, for example, to make comfy chairs or mattresses that prevent bedsores. To produce these, the support is formed in such a way that the contact surface is large which, as a result, lowers the pressure on parts of the body. This type of programmable material is being developed by researchers at the Fraunhofer Cluster of Excellence Programmable Materials CPM, who plan to bring it to the market with the help of industry partners. One of their goals is to reduce the use of resources.

Additive manufacturing of tools using a laser powder bed fusion process offers a great number of advantages: It is economical, precise and allows for customized solutions. That said, it can be difficult to determine the optimal process parameters, such as the scan speed or power of the laser. For the first time, researchers at Fraunhofer are now simulating the process at the microstructure level in order to identify direct correlations between the workpiece properties and the selected process parameters. To do this, they are combining a number of different simulation methods.

20 percent of the energy generated worldwide is lost through friction. With new materials, surfaces and lubricants, 40 percent of this energy could be saved in the long term — equivalent to CO2 emissions of more than three gigatons per year! Superlubricity in machine elements is one way to achieve this goal. Fraunhofer researchers are working to bring superlubricity from the laboratory into real-world application.

Oil is a well-known and widely used lubricant — less commonplace, however, is the solid lubricant graphite. Although graphite is used at low-contact pressure, the effects that occur here had previously only been understood to a limited extent. It was particularly unclear whether this lubricant could also be used at high-contact pressure, such as it occurs in rolling bearings. Researchers were now able to expand the current friction model to explain these effects. In a recently published article in the journal Nature Communications, they specify how their findings pave the way for the future use of graphite lubrication in high-pressure applications.

Practical and environmentally friendly, e-scooters offer great flexibility. It is no wonder that more and more people are using this form of transport. However, this rise in popularity has been accompanied by an increase in accidents resulting in severe injuries. The risk associated with these speedy runabouts is widely underestimated. In response to this, Fraunhofer researchers studied a typical accident scenario and the associated injuries as part of the HUMAD project. The experts also tested novel materials for helmets and protective gear. These could provide much better protection than conventional products.

Global challenges such as climate change, renewable energy and individual mobility increase the necessity for a more efficient and sustainable use of our resources. Programmable materials have the potential to initiate a paradigm shift in the design and use of materials by replacing technical systems of many components and materials with a single, locally configured one. The first international conference on programmable materials aims to facilitate this paradigm shift for materials science. It creates the interdisciplinary scientific platform to accelerate the development, production and application of programmable materials. For more info, registration and for detailed program information visit www.progmatcon.com. #ProgMatCon22

Ensuring that power plants operate without breaking down and that vehicles run energy-efficiently ultimately depends on just a few atoms. A virtual material probe makes it possible to see, and therefore control, tribological processes at the atomic level. A team of researchers from the Fraunhofer Institute for Mechanics of Materials IWM is being awarded the Stifterverband Science Prize 2022 for this development.

To ensure that steel delivers what it promises, its microstructure is analyzed in detail to detect weak points during early stages. Today, this is largely done via visual inspection. Component manufacturers have long desired an automated image analysis method. In a cooperative project, the Fraunhofer IWM has now developed such a method based on neural networks. It delivers reliable and reproducible results and is a fundamental building block for the end-to-end digitalization of steel processing within Industry 4.0. The results have now been published in the scientific journals “Nature Communications” and “npj – computational materials”.

In materials and component research, artificial intelligence methodologies will lead to massive upheavals in the coming years. The processes of material development, material processing, lifetime prediction and material characterization will change significantly. By combining AI methods and new forms of knowledge representation, the data-based management of product life cycles will take on new qualities. To address this emerging field of research Fraunhofer IWM set up the online workshop »AI Methods for Fatigue Behavior Assessment and Component Lifetime Prediction« on November 24 and 25, 2021.