Adhesives accelerating innovation.


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

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Adhesives accelerating innovation.

  1. 1. Adhesives Accelerating Innovation W. Cavalcanti, B. Mayer Fraunhofer Institute IFAM Bremen, Germany Sept. 24, 2012 © Fraunhofer IFAM 1
  2. 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) © Fraunhofer IFAM 2 expected value
  3. 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 © Fraunhofer IFAM 3 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. 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. © Fraunhofer IFAM 4
  5. 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 © Fraunhofer IFAM 5
  6. 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 © Fraunhofer IFAM 6
  7. 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 © Fraunhofer IFAM 7 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. 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 © Fraunhofer IFAM 8 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. 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 © Fraunhofer IFAM 9 generating, distributing and use of electrical energy closed loop production
  10. 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 © Fraunhofer IFAM 10
  11. 11. Material Science at University of Bremen “ambitious and agile“ “ambitioniert und agil“ © Fraunhofer IFAM 11
  12. 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 © Fraunhofer IFAM 12
  13. 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 © Fraunhofer IFAM 13
  14. 14. Adhesive Bonding and Surface Technology technical systems focusing on interfaces  molecules - materials - manufacturing technologies  Adhesive Bonding  Surface Technology and Coatings  Fiber Reinforced Plastics      © Fraunhofer IFAM 14 material development material characterization application processes structures quality management
  15. 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 © Fraunhofer IFAM 15
  16. 16. L IGHT W EIGHT M ATERIALS Functional Surface Systems © Fraunhofer IFAM 16 erosion protection corrosion protection wetting drag reduction
  17. 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 © Fraunhofer IFAM 17
  18. 18. Riblet-type Structures  shaping and curing in a single stage © Fraunhofer IFAM 18
  19. 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 © Fraunhofer IFAM 19
  20. 20. JOSEF-VON FRAUNHOFER INNOVATION AWARD 2012 corrosion protection hydrophobicity hydrophilicity Dr. Jörg Ihde, Dr. Uwe Lommatzsch © Fraunhofer IFAM 20 anti-adhesion coatings protective coating electronics (demolding)
  21. 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 © Fraunhofer IFAM 21
  22. 22. 3D Deep-drawing Process, Vacuum-assisted © Fraunhofer IFAM 22
  23. 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 © Fraunhofer IFAM 23
  24. 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 © Fraunhofer IFAM 24
  25. 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 © Fraunhofer IFAM 25
  26. 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 © Fraunhofer IFAM 26 non-tacky and good wetting
  27. 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 © Fraunhofer IFAM 27 0 0 10 20 30 time [s] 40 50 60
  28. 28. Interfaces between Biology/Chemistry and Materials I. PROTEIN BASED ADHESIVES  hybrid adhesives  marine adhesives © Fraunhofer IFAM 28 II. BIO-FUNCTIONALIZED SURFACES  hybrid materials  sensorics III. BIO-COMPATIBLE SURFACES  bio active  bio stable
  29. 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 © Fraunhofer IFAM 29  formulating “conventional” adhesives using such peptides as components  such biomimetic hybrid adhesives show promise for bonding soft tissue
  30. 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 © Fraunhofer IFAM 30 Prof. Dr. Bernd Mayer
  31. 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 © Fraunhofer IFAM 31 DVS®-EWF-European Adhesive Specialist - EAS (DVS®-EWF-Klebfachkraft)  establish work instructions, guide workforce target group: master and supervisor
  32. 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 © Fraunhofer IFAM 32
  33. 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) © Fraunhofer IFAM 33
  34. 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 © Fraunhofer IFAM 34
  35. 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 © Fraunhofer IFAM 35
  36. 36. Conclusion MISSION: IMPOSSIBLE © Fraunhofer IFAM 36 MISSION: POSSIBLE