Contributions of the Business Unit Mechanical Engineering, Tools and Automotive Technology

 

Development of a sensory kingpin

At the Fraunhofer IST, a piezoresistive thin-film system for force measurement was developed, which is directly precipitated onto the complex shape of the mechanical connecting link between tractor unit and trailer, the so-called kingpin.

 

Innovative sensor systems for production monitoring

Various application-specific sensor systems on components are being developed at Fraunhofer IST.

 

Lubricant-free cold forming of aluminum sheets

An approach for the economically and ecologically more efficient cold forming of aluminum sheets is provided by the Fraunhofer IST in the form of a tool coating on the basis of amorphous hydrocarbon (a-C:H).

 

Thermal shock resistant tool surfaces

In order to minimize wear in production, the Fraunhofer IST optimizes tool surfaces that are stressed by thermal shock.

 

Prediction of plasma nitriding results

At the Fraunhofer IST, a prediction tool has therefore been developed forecasting the results of plasma nitriding processes, thereby, enabling an improvement in the quality of treated components.

 

Plasma replaces adhesive

The Fraunhofer IST is working together with project partners on a solution for the scaling-up of a new ­inline-capable joining process for the production of such composite materials from metal and plastic films.

 

Compact jet-induced sliding discharge source

 At the Fraunhofer IST, a plasma source concept based on a jet-induced sliding discharge has been developed which enables the effective activation or functionalization of even geometrically challenging contours.

 

Sensors for NFR manufacturing

At the Fraunhofer IST, multifunctional coating systems are being developed for the reduced wear production of natural fiber-reinforced plastics.

 

Manufacturing of sensor systems

The customer request is the focus of sensor developments at the Fraunhofer IST. This involves the geometry of the base body, as well as the number of the sensor systems.

 

Forming titanium alloys efficiently

The Fraunhofer IST develops anti-adhesive tool coatings for high-temperature forming of titanium, with these coatings more efficient forming processes should be achieved.

 

Textured CVD diamond honing stones

At the Fraunhofer IST diamond honing stones have being developed and successfully tested, which show several advantages relative to conventional honing stones.

 

Gas boriding of high alloy tool steels

Through newly developed processes at the Fraunhofer IST now high alloy tool steels can also be effectively handled with this process.

 

Thermal shock testers for tools

An innovative thermal shock test stand for evaluation of the edge layers with regard to their resistance to thermal shock has been developed at Fraunhofer IST.

 

Process chain for the pretreatment

The Fraunhofer IST has developed a new process chain for the pretreatment of tools and evaluates this process chain relating to the application with industrial partners.

 

HIPIMS-Arc mixed mode deposition

At the Fraunhofer IST work is currently underway on an alternative manufacturing method: combined HIPIMS-Arc mixed mode deposition.

 

DLC coatings for forming

At the Fraunhofer IST a combination of nitriding and DLC coating is used to increase the resistance of the DLC coatings, particularly on tools.

 

Structure-preserving hard coatings

At the Fraunhofer IST the conditions for an optimum design of the die surface and its successful preservation could now be defined.

 

Dry forming of aluminum alloys

The Fraunhofer IST develops coating systems which make dry forming processes possible for aluminum alloys.

 

Temperature measurement in die-cast aluminum

The Fraunhofer IST has been obtained in implementing thin-film sensor systems as a coating directly on the mold surface.

 

Sensor-controlled moment connections

For monitor building structures, various modules with sensorized thin-film systems were constructed at the Fraunhofer IST.

 

Heating conductors for plastic injection molds

At the Fraunhofer IST, conditions were defined for optimum die surface design and its successful preservation.

 

Anti-adhesive coatings for plastic molding

The Fraunhofer IST is working on cost-effective coating solutions which reduce cycle times, facilitate demolding and increase quality.

 

Washer sensor systems

For many years now the Fraunhofer IST has a broad cross-industry expertise in sensor technology, coating development and micro structuring. Lately a new kind of washer sensor based on the piezoresistive thin film DiaForce® has been developed.

 

Sensor system for the deep-drawing process

A multifunctional thin film system was developed for the local measurement of pressure and temperature distribution over the surface of deep-drawing dies.

 

Pretreatment of high-performance plastics

Atmospheric-pressure plasma pretreatment for high-strength plastics has been optimized at the Fraunhofer IST.

 

Magnetic layers with gas flow sputtering

For some time now soft and hard magnetic layers for different applications have been developed at the Fraunhofer IST.

 

Antifouling coatings for pipes

Together with partners the Fraunhofer IST has developed a new approach to manufacturing pipes with an anti­fouling coating on the inside of the pipe.

 

Thermally stable DLC coatings

Differently modified DLC coatings have been investigated at the Fraunhofer IST with regard to their mechanical and tribological properties up to 550 °C.

 

Insulation coatings with dielectric strength

Research is in progress at the Fraunhofer IST into processes by which defect-free insulating coatings can be produced on the industrial scale.

 

Sensor modules for the sheet-bending process

At the Fraunhofer IST a new kind of thin-film sensor system is being developed which stands in direct contact with the workpiece to be formed.

 

Interlayers for the diamond coating

At the Fraunhofer IST interlayers are being developed as alternatives to a process which has to date been essential: