Reference projects of the Fraunhofer IST

With the objective of reducing the energy consumption as well as CO2, noise, and brake-dust emissions when using vehicle trailers, an innovative electric propulsion and control system has been developed for vehicle trailers within the framework of the “ev(electric vehicle)Trailer” project funded by the BMWi. The outstanding feature is the manufacturer-independent autonomous mode of operation of the evTrailer, which functions with any conventional tractor unit.

Toxic cobalt, which is mined under inhumane and environmentally destructive conditions, has long been an essential component of high-performance tools used to machine composite materials and light metals for wind power and electric vehicles, amongst other applications. »Green« cutting tools made from cobalt-free carbides and novel robust diamond and hard-material coating systems are to be developed and made available for key German industries.

In the 16 sub-Saharan African countries, at least 40% of the population corresponding to more than 130 million people have no access to safe water. The aim of the project was to research and develop an autonomous and decentralized ˝Made in Africa˝ water treatment system for rural and periurban areas which is highly efficient in the degradation of harmful pollutants and which is accepted by the rural communities.

PEM fuel cells have great potential for reducing greenhouse gas emissions, but are limited by uneconomical mass production. In the project ‘Development of production-process sequences for coated metallic bipolar plates for fuel cells of the highest quality and energy efficiency’, the Fraunhofer IST is working together with the Fraunhofer Institutes IWU and IWS on improving the properties, increasing the lifespan and developing and testing new production methods for metallic bipolar plates. This involves combining two coating approaches and forming processes.

Through the description of the following reference project, we would like to provide you with the opportunity to obtain your own impression of the potential of the various diffusion treatments. In the process, you will gain an insight into the specific problem and the challenges encountered, the solutions pursued by the Fraunhofer IST, the findings obtained, and the consequent benefits resulting from and beyond the project.

Seal-less rolling bearings that can be used under media lubrication possess a high potential for utilization in energy-efficient and resource-saving applications. Under these highly tribocorrosive conditions, standard rolling-bearing materials can only be used to a very limited extent. Within the framework of the POSEIDON II project, cost-effective novel steels are optimized by means of edge-layer treatments using adapted low-temperature plasma-diffusion treatment.

Climate change and the associated extreme weather conditions combined with the expanding human population are causing severe permanent or temporary water stress in many regions of the world. The joint ICON project WASTEC, conducted by Fraunhofer and Stellenbosch University, aims to develop strategies for addressing the serious threats to water demand and quality within the two broad themes of the desalination and re-use of water.

Energy imports into Germany covered around 74 percent of the country’s primary energy consumption in 2019 and are dominated by fossil fuels such as hard coal. As a result of the energy transition, the seaport location of Wilhelmshaven will have to undergo a transformation process in record time, thereby developing into a hub for low-carbon and renewable energy sources such as hydrogen (energy hub). The Fraunhofer IST is supporting this process as a scientific partner through its expertise in the field of energy storage and systems.

Metallized plastic components are used in the automotive industry in order to furnish lightweight and inexpensive plastics – such as ABS – with a high-quality surface. Galvanic plastic metallization, however, requires a chemical pre-treatment which will be banned in the near future due to the health hazards of the thereby utilized chromium(VI) compound. In the Fraunhofer-internal project “REAKOLA”, carried out in collaboration with the ILT, a laser-based process was developed which does not require chemical pre-treatment of the plastic surface and which will enable REACH-compliant galvanic metallization in the future.

Carbon-fiber-reinforced plastic (CFRP) is a magical material in aerospace: super-lightweight and extremely mechanically resilient. In its original state it is, unfortunately, neither electrically conductive nor solderable. In a joint project with Airbus DS, a process was developed in order to metallize CFRP and consequently make it electrically conductive and solderable. The resulting product was then used to coat CFRP waveguides which, as antennas for the ESA Sentinel 1 mission, fly around the Earth in low earth orbit.