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Annual Report 2010 FRAUNHOFER INSTITUTE FOR MATERIAL AND BEAM TECHNOLOGY IWS DRESDEN ANNUAL REPORT 2010 www.iws.fraunhofer.de FRAUNHOFER INSTITUTE FOR MATERIAL AND BEAM TECHNOLOGY IWS ANNUAL REPORT 2010 Fraunhofer IWS Annual Report 2010 1 PREFACE Today’s technology is tomorrow’s bread – today’s science is tomorrow’s technology. Richard von Weizsäcker The economic crisis still shaped the beginning of 2010. A significant improvement of the eco- nomic climate during the second half of the year, however, led to record industrial revenues for the Fraunhofer IWS. A 10 % growth was achieved with about 8.5 million euros. The simul - taneously increased acquisition of publicly funded projects contributed to an extraordinarily successful 2010 business year. A production technology project addressing the fabrication of lithium ion batteries presents an outstanding example of IWS efforts, which are shared by several departments. Another interest- ing challenge being addressed in the field of energy production is a project to break up natural gas into hydrogen and carbon by using solar power. The country of Qatar and the State of Saxony are co-sponsoring this project. Her royal highness, Sheikha Mozah Bint Nasser Al Missned, personally signed the agreement during a visit in Germany. Since 2009, the Fraunhofer IWS has performed several larger projects in the field of energy research. One of the very successful efforts addresses energy efficiency improvements by reducing friction losses. In this project the IWS is partnering with the University of Technology (TU Dresden) under the coordination of BMW. The institute has clearly increased its engagement in energy relevant research; however 2010 also saw plenty of traditional IWS strengths in commercializing in-house developed technolo- gies. A successful industrial implementation always marks a highlight for the IWS as well as the Fraunhofer-Gesellschaft. This report will present some examples. In 2010 the IWS further strengthened its scientific collaboration with the TU Dresden and additional research institutions in Dresden such as the Leibniz and Helmholtz institutes. These efforts are coordinated within the DRESDEN-concept initiative. It appears that the economic crisis is resolving. Industry inquiries for R&D services are increasing and government project solicitations are on the rise as well. The Fraunhofer IWS is well posi- tioned. We expect a substantial growth for 2011 and are starting the year positively. Eckhard Beyer Fraunhofer IWS Annual Report 2010 3 CONTENTS NEWS FROM THE FRAUNHOFER IWS PREFACE 3 CONTENTS 4 HIGHLIGHTS OF 2010 6 NEWS FROM THE BOARD OF TRUSTEES 10 INSTITUTE PROFILE 12 CORE COMPETENCES 12 INSTITUTE IN NUMBERS 14 ORGANIZATION AND CONTACTS 16 NEWS FROM BUSINESS FIELDS ABLATION AND CUTTING 18 THE LASER AS A TOOL FOR CUTTING AND MICRO PROCESSING JOINING 34 NEW JOINING TECHNOLOGIES FOR METALLIC AND NON-METALLIC MATERIALS SURFACE TREATMENT 46 COMPREHENSIVE MATERIALS, PROCESS AND SYSTEM TECHNICAL APPROACH 4 Fraunhofer IWS Annual Report 2010 THERMAL COATING 58 SYMBIOSIS BETWEEN COATINGS TECHNOLOGY AND MATERIALS KNOW-HOW ATMOSPHERIC PRESSURE CVD COATING TECHNOLOGY 68 NEW TECHNOLOGIES IMPROVE FUNCTIONALITY OF SURFACES PVD VACUUM COATING TECHNOLOGY 82 NOVEL COATINGS SYSTEMS EXPAND APPLICATION SPECTRUM NETWORKS, NAMES, DATES PRICES AND HONOURS 2010 98 NETWORKS 100 THE FRAUNHOFER-GESELLSCHAFT 101 CONNECTION TO THE TU / DRESDEN-CONCEPT 102 DIZEEFF 104 DOC / PCW 106 CCL 108 NANO / LIFT 110 FRAUNHOFER GROUP ”LIGHT & SURFACES” 112 SPECIAL EVENTS 114 PUBLICATIONS 116 ADDRESS AND DIRECTIONS 121 Fraunhofer IWS Annual Report 2010 5 HIGHLIGHTS OF 2010 ENERGY RESEARCH AT THE FRAUNHOFER IWS RESEARCH COOPERATION WITH QATAR FOR SOLAR THERMAL HYDROGEN PRODUCTION Innovations in energy research are more important than ever to secure the future for the economy and society. The The first joint research project between the Fraunhofer- Fraunhofer IWS considers it a priority to work on the imple- Gesellschaft and the Qatar Science & Technology Park (QSTP) mentation of modern energy technologies. In 2010 the IWS began on September 30th 2010. The project’s objective is to acquired energy related research projects from industrial and develop a climate neutral process producing hydrogen and government funding sources worth 5 million euros. These carbon particles using solar energy. QSTP and Fraunhofer IWS projects aim at improving energy conversion, storage and effi- are jointly developing a novel solar reactor that applies con- ciency. In addition, the institute invested 1 million euros of centrated sunlight to break up methane into hydrogen and internal funds in basic energy research and technology devel- carbon particles. This process substantially contributes to opment. Two particularly important projects will be discussed reduce CO2 emissions. here. Another article describing the DRESDEN-concept initi- ated DIZEeff project follows on pages 104 / 105. PRODUCTION TECHNOLOGY DEMONSTRATION CENTER FOR LITHIUM ION BATTERY CELL FABRICATION – DELIZ The collaborative research project DeLIZ (project funding identifier 02P02640) was started in 2010. The collaboration includes researchers from Fraunhofer IWS, TU Dresden and TU Munich. The team researches the process chain of manu- facturing lithium ion battery cells. Novel solutions are sought to enable cost efficient high volume manufacturing, efficient quality control systems and innovative fabrication methods with the goal to rapidly transfer the technologies to produc- DRESDEN’S CONFERENCE “FUTURE ENERGY” tion. Research foci include the energy efficient coating of electrodes in roll-to-roll processes, the cost efficient manu- The conference “Future Energy” will be held in Dresden facturing, the automation of handling and cell fabrication, the from May 11th - 13th 2011. The Fraunhofer IWS and the TU setting of individual foils and the joining of foil packages with Dresden will jointly present research results which will include minimal contact resistance as well as the fabrication of stable those projects discussed above. Representatives from politics, Al-Cu contacts for the packaging of individual cells. All areas science and industry are invited and they will be presenting require the development of concepts, technologies and sys- their results, products and experiences in energy conversion, tems. First results are presented on pages 78 / 79. storage and efficient utilization. Additional information can be found at: http://www.zukunftenergie-dresden.de Fraunhofer IWS Annual Report 2010 7 HIGHLIGHTS OF 2010 2 THE FIFTH LASER-BASED CUTTING MACHINE FOR FLEXIBLE REPAIR OF JET ENGINE COMPONENTS BY LASER AIRBAGS WAS TRANSFERRED TO INDUSTRY POWDER BUILDUP WELDING USING IWS COMPONENTS Fraunhofer IWS engineers in collaboration with the company Together with the machine manufacturer Arnold, IWS engi- Held Systems Deutschland GmbH have developed a compact neers implemented a new automated precision laser buildup system for the flexible laser cutting of airbag material. In 2010 welding system for the repair of engine components (Fig. 2). another unit was transferred to an industrial customer for pro- The customer is MTU Aero Engines in Munich. The system duction duty. The company Autoliv Poland Restraint Systems is contains an optical geometry detection unit that determines the largest manufacturer for automotive safety components in the location and given surface conditions of the damaged the world. The advantage of the highly productive system is part. Based on the data, special software calculates the opti- the constant quality of the insert cut, which is cut out from an mal buildup welding strategy. Immediately after calculation up to 3 m wide material strip, and its higher throughput com- the buildup welding process is performed with an accuracy pared to the conventional multilayer cutting process. of a tenth of a millimeter using IWS COAXn series powder nozzles. An IWS developed process control system provides an HANDOVER OF A ROBOT BASED LASER SYSTEM FOR important contribution to quality control. The system has been HARDENING AND BUILDUP WELDING OF TOOLS used in high volume production since September of 2010. An application example is the repair of blade tips, which is per- In 2010 a robot based laser system to process cutting and formed at 30 % reduce processing time. forming tools was implemented at Audi AG in Ingolstadt (Fig. 1). The laser hardening and buildup welding system was SECOND SYSTEM IMPLEMENTED IN INDUSTRY FOR THE developed jointly with KUKA Roboter GmbH. The machine is LARGE AREA PRECISION COATING OF X-RAY OPTICAL especially adapted to build new, and repair existing, tools for COMPONENTS car body making. The Fraunhofer IWS delivered special system components for beam shaping, process control and powder The refraction and reflection of EUV or x-ray radiation requires feed as well as modules for the assembly of the robot hand. specially coated surfaces. IWS engineers worked very closely The engineers also determined process parameters for the dif- with Saxony’s Roth & Rau Micro-Systems GmbH to develop ferent applications and coordinated the startup of the process and implement an appropriate system design tailored to the control systems. special requirements of an industrial customer (Fig. 3). The system includes 6 coating sources, which makes it especially productive. Substrates of up to 680 mm can be handled. The system is used for the coating of EUV or x-ray optical compo- nents in analytical tools for medical application. A future use in lithographic systems
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