Fraunhofer Institute for Mechanics of Materials IWM
Fraunhofer Institute for Mechanics of Materials IWM

Substitution of critical raw materials

© FraunhoferIWM
γ‘ particles in the nickel-based alloy MAR-M247: In the as-received condition (top left) and after aging in a laboratory furnace at 1000 °C for 1000 hours (top right).

Regulatory requirements, limited availability, changing operating conditions, and new customer demands often necessitate the substitution of critical raw materials and the design of new materials functionality in many applications. Only with the appropriate knowledge base regarding properties and behavior can the necessary technological decisions be made to develop new materials solutions while meeting economic and environmental constraints.

Examples of specific challenges we address in projects:

  • Variation of chemical materials composition to achieve target properties
  • Optimization of heat treatments
  • Extension of service life by adjusting residual stress conditions
  • Minimization of dimensional changes during manufacturing and use
  • Reproducibility and scalability: from prototype to series production

Substitution of Critical Raw Materials — Use Cases

We make materials predictable. In our application examples, we demonstrate how we work and how our various R&D services work together to create a comprehensive solution.

 

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Substitution of Critical Elements in Nickel-Based Alloys

The substitution of critical alloying elements contributes to the economic and technical sustainability of nickel-based alloys used in demanding applications, such as aerospace and energy technology. Many critical alloying elements are subject to significant price fluctuations and regulatory requirements, or are available only in limited quantities.

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Substitution of Beryllium in Copper Alloys

Copper-beryllium alloys (Cu-Be) are characterized by their high strength and electrical conductivity and are therefore often used in electrical connectors. However, beryllium is harmful to health and is produced in only a few countries outside Europe, creating a supply risk. Therefore, there is a strong need to find alternatives that retain the excellent properties of Cu-Be alloys. 

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Corrosion Protection with Copper-Based Coatings

Nickel coatings are used where components need to be protected against corrosion, wear, or mechanical stress, and where a high-quality surface finish is desired. They offer high dimensional accuracy and hardness, are characterized by good optical properties, and their electrical conductivity can be tailored.  However, complex deposition processes, the use of cyanide-containing electrolytes, and potential allergic reactions limit their application. 

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Laser Shock Peening Instead of Shot Blasting to Extend the Service Life of Components

Laser shock peening (LSP) is a promising alternative to conventional shot peening for increasing the service life of components, particularly under fatigue loads. Shot peening is very cost-effective, but small changes in process parameters and wear can lead to undesirable weakening of materials.

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Service Life Assessment of Aluminum Alloy Compressor Impellers

Radial compressor impellers, such as those used in exhaust gas turbochargers for internal combustion engines, are subject to stringent requirements regarding their structural durability. The aluminum alloy EN AW-2618A is the predominant material for these components due to its good creep and fatigue strength. However, aging during high-temperature operation leads to a change in microstructure, which is associated with a loss of strength and thus a reduced service life. 

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