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

1. Adhesives Accelerating Innovation
W. Cavalcanti, B. Mayer
Fraunhofer Institute IFAM
Bremen, Germany
Sept. 24, 2012
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2. The Fraunhofer-Gesellschaft
 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 Forschungsgemeinschaft (DFG) and the Max-Planck-Gesellschaft (MPG)
 2012:
60 Fraunhofer-institutes
>21,000 employees, mainly with background in natural sciences or engineering
1,97 billion Euros1) annual research budget
1)
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expected value

3. Joseph
von Fraunhofer
(1787-1826)
discovery of the
“Fraunhofer lines” in
the solar spectrum
new methods for
processing lenses
director and partner in
a glassworks
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Fraunhofer
Gesellschaft
Researcher
research and
development on behalf
of industry and state
Inventor
mp3 music format,
white LED, high-resolution thermal camera
Entrepreneur
research volume
approx. 1.9 billion
Euros annually

4. Mission of the Fraunhofer-Gesellschaft
Fraunhofer-Gesellschaft promotes and undertakes applied research in an international context, 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 develop professional and personal skills to
assume positions of responsibility within their institute, in industry and in other scientific domains.
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5. Profile of the Fraunhofer-Gesellschaft
7 Divisions:
 Information and Communication Technology
 Life Sciences
 Microelectronics
 Light & Surfaces
 Production
 Materials and Components - MATERIALS
Materials and Components - MATERIALS
 Defense and Security
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6. Fraunhofer Division “MATERIALS“
MATERIALS RESEARCH ACROSS ENTIRE VALUE CHAINS
from developing new materials through quasi-industrial scale manufacturing technology to the characterization of properties and assessment
of service behavior. Covering components their functions, as well
CORE COMPETENCIES
material development
component and system reliability
technology development
materials modeling and simulation
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7. Fraunhofer Division “MATERIALS“
MATERIAL DEVELOPMENT
 ”smart“ materials and
components
 (functional) polymers with
specific electrical, electrooptical and optical properties
 fibers and fiber composites,
advanced ceramics, nanomaterials, semiconductors,
phase change materials
 active layers (photo catalysis,
electrically adjustable layers)
 bio-based materials
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TECHNOLOGY
DEVELOPMENT
 coatings, surface modification, multi functional
materials
 light metal casting, rapid
prototyping, microforming,
cellular materials
 process technology
 joining technologies and
machining procedures
 testing technology

8. Fraunhofer Division “MATERIALS“
COMPONENT AND
SYSTEM RELIABILITY
 … of materials, components
and systems
 … in terms of structural
durability, system reliability,
functionality
 analysis, characterization
 destructive and nondestructive testing (NDT),
assessment
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MATERIALS MODELING
AND SIMULATION
 simulation technologies
 multi-scale simulation
 modeling and simulation
from elementary material
properties, materials
development and production to service behavior of
components and systems

9. Global Objectives
Health and Nutrition
Protection and Safety
Mobility and Traffic
affordable health
recognizing and control of
disasters
low emission and reliable
mobility in urban areas
Information and
Communication
Energy and Habitation
Production and
Environment
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generating, distributing and
use of electrical energy
closed loop production

10. 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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11. Material Science at University of Bremen
“ambitious and agile“
“ambitioniert und agil“
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12. 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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13. Certification / Accreditation




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
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14. Adhesive Bonding and Surface Technology
technical systems focusing on interfaces
 molecules - materials - manufacturing
technologies
 Adhesive Bonding
 Surface Technology and Coatings
 Fiber Reinforced Plastics





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material development
material characterization
application processes
structures
quality management

15. 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 microstructural analyses
optical / mechanical properties, wetting
production-integrated quality assurance
failure analysis
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16. L IGHT W EIGHT M ATERIALS
Functional Surface Systems
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erosion protection
corrosion protection
wetting
drag reduction

17. Shark Skin for Transportation and Wind Energy
Nature as Model
Shark skin has a specific structure minimizing flow resistance. Challenge was to transfer 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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18. Riblet-type Structures
 shaping and curing in a single stage
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19. Riblet-type Structures
 continuous application on large surfaces
demand for economic
reproducing method of
surface topologies
solution: combined application
and embossing processes based
on UV-curable resins
(1) shaping tool with negative microstructure 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
moving direction
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20. JOSEF-VON FRAUNHOFER INNOVATION AWARD 2012
corrosion
protection
hydrophobicity
hydrophilicity
Dr. Jörg Ihde, Dr. Uwe Lommatzsch
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anti-adhesion coatings
protective coating
electronics
(demolding)

21. Example – Plasma Coatings for De-molding
Release properties of
plasma coatings
 de-molding of CFRPcomponents
 conventional release
coatings need rework
 best release effect by
ND plasma coating
without rework
 up to 40 de-molding
cycles proven
 further optimization
ongoing
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22. 3D Deep-drawing Process, Vacuum-assisted
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23. 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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24. 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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25. Bonded Structures - Simulation and Modeling
 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
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26. Pre-applicable Structural Adhesives (“PASA”)
customer- and
application-related
specifications
fast
cure and
long shelf life
norms and
legal
requirements
pre-applicable
structural
adhesives
good adhesion
in uncured state
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non-tacky
and good wetting

27. Pre-applicable Structural Adhesives PASA
induction heating
example: bonding bolts
 pre-application of epoxy-based
reactive hotmelts
 tack-free up to 50 C
 induction heating
temperature [°C]
200
150
100
50
 fast curing within seconds
 integrated development of
adhesive formulations, warming
process and part geometry
 development of application
process necessary
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0
0
10
20
30
time [s]
40
50
60

28. Interfaces between Biology/Chemistry and Materials
I. PROTEIN BASED
ADHESIVES
 hybrid adhesives
 marine adhesives
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II. BIO-FUNCTIONALIZED
SURFACES
 hybrid materials
 sensorics
III. BIO-COMPATIBLE
SURFACES
 bio active
 bio stable

29. Biomimetic Medical Adhesives
Medical Engineering
 blue mussel able to adhere to
low energy surfaces
 glue is based on DOPA
containing peptides
 synthesis of peptides containing
DOPA
Mytilus edulis
blue mussel shell
DOPA
dihydroxyphenylalanine
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 formulating “conventional” adhesives using such peptides as
components
 such biomimetic hybrid adhesives show promise for bonding
soft tissue

30. Focus Quality
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
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Prof. Dr. Bernd Mayer

31. Training Programs - Employee Qualification
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 Engineer - EAE
(DVS®-EWF-Klebfachingenieur/in)
 develop / implement adhesive bonding processes
target group: technical management level
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www.kleben-in-bremen.de
DVS®-EWF-European Adhesive Specialist - EAS
(DVS®-EWF-Klebfachkraft)
 establish work instructions, guide workforce
target group: master and supervisor

32. 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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33. CFRP Research Center Stade
Innovation
Works (IW)
joining techniques
machining
textile technologies
light weight design
components
virtual CFRP-development
application research
(e.g. new resins)
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34. Automated Assembly and Machining
Adhesive Bonding
 Fully automated processing
 One-step shim assembly
 Fast curing adhesives / shims
 Design flexible cell layout
Simultaneous machining
 Failure preventing process
control
 Automated drilling and milling
 Preventing thermal damage and
delamination at cutting area
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35. Automated Measurement and Positioning
Objectives
Enabling low cost standard robotics:
 achieve higher precision
 process parts with high geometrical deviations
 compensate part deformation
caused by process forces
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36. Conclusion
MISSION: IMPOSSIBLE
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MISSION: POSSIBLE