AdHyBau: Hybrid construction methods with generative metal structures and fiber composites for high-performance electric motors

Project description

As part of the AdHyBau research project, Fraunhofer IWM and its project partners developed new additive processes and fiber composite-metal hybrid construction methods for use in cryogenic environments. End-to-end design, simulation, and material qualification processes were established to commission a novel electric drive as a virtual prototype. The combination of high-performance fiber composite materials with additively manufactured metallic elements enabled structures that were significantly enhanced in functionality and performance, such as optimized cooling systems and a specific coil design to increase the power density of electric motors.

Fraunhofer IWM subproject

Fraunhofer IWM was responsible for material qualification and service life prediction of additive materials in a hydrogen atmosphere and at cryogenic temperatures. While modeling of materials and component design for high-temperature applications had been part of Fraunhofer IWM’s expertise for many years, new test benches were set up and test strategies were developed for material qualification at low temperatures, especially considering the influence of hydrogen. The aim was to enable the use of additively manufactured materials under the specified environmental conditions.