Mechanical and Plant Engineering

Machine and plant engineering is one of the main target groups of the laser-based systems and process technologies developed at Fraunhofer ILT. New high-performance beam sources and optical systems as well as highly efficient laser-based manufacturing processes give mechanical engineering the leverage to create new process chain solutions and business areas, as well as help users to create new products and to lower production costs., Fraunhofer ILT has a deep understanding of these processes - particularly in the manufacturing sector – such as laser cutting, laser welding, structuring and drilling techniques, as well as additive manufacturing. This is based on many years of experience in the simulation and modeling of laser technology. The institute supports its cooperation partners in selecting application-specific beam sources, in optimizing process efficiency and product quality through adapted optics systems and in using high-power process monitoring systems. It also cooperates with its R&D partners in commercializing and licensing its developments.

The digitization of industrial production makes the integration of sensors and process monitoring systems more important. The model-based planning of process chains and sensor-integrated implementation, as envisioned in Industry 4.0 concepts, makes it possible to create digital shadows of process flows, products and plants. Digital Photonic Production is a focal point at Fraunhofer ILT and makes an effective contribution to Industry 4.0.

The Digital Photonic Production research campus is systematically driving forward the interplay between laser processes and the digitally networked world. Particularly in the field of 3D printing and ultra-precision machining, Fraunhofer ILT is developing new approaches in close cooperation between science and industry to develop innovative laser systems and production processes. With the possibilities of artificial intelligence and Industry 4.0, process control will achieve a new quality in the future.

We address the challenges that drive your industry!

Additive manufacturing and Industry 4.0

Selective laser melting process in the production of a gas turbine component at MAN Diesel & Turbo SE.
© Fraunhofer ILT, Aachen, Germany.

Selective laser melting process in the production of a gas turbine component at MAN Diesel & Turbo SE.

Component and process development, system integration, design of material properties or individual consultation: Fraunhofer ILT offers extensive expertise in the field of additive manufacturing (AM), whereby the robust AM processes stand in the foreground. In addition, the importance of digitizing process chains is growing – which is a key component of Industry 4.0. The institute works on ensuring the consistency of the data, from the CAD design through simulations and manufacturing processes to the quality assurance of produced components. Data are recorded in real time, then evaluated and fed into appropriate control loops. Directed by Fraunhofer ILT, research institutes are developing a comprehensive system of data management and service - the first blockchain in the area of additive manufacturing. In particular, the institute helps small and medium-sized companies implement their ideas in the field of additive manufacturing.

In particular, additive manufacturing can be used in sectors that place the highest demands on design and material properties with regard to individualized or complex components. In this regard, Fraunhofer ILT focuses on both laser material deposition (LMD) and laser-beam melting. To exploit the freedom in choosing materials for the latter process, the Fraunhofer ILT is investigating, for example, the specification limits of powder particle sizes and the use of less expensive powder production methods.

Real-time process monitoring for laser welding and cladding

Alignment of powder focus, position of the processing laser radiation (green) and measuring radiation of the "bd-1" (red).
© Fraunhofer ILT, Aachen, Germany.

Alignment of powder focus, position of the processing laser radiation (green) and measuring radiation of the "bd-1" (red).

Fraunhofer ILT is developing various systems for real-time process monitoring, which offer more economical production and improved quality assurance. The result of the EU research project “MAShES ” (Multimodal Spectral Control of Laser Processing) is, for example, a multispectral, imaging sensor system for process monitoring. This can be integrated into laser processing optics and used in welding and cladding. In real-time, different sensor data streams are analyzed simultaneously during the process, creating a clear fingerprint of the process. This fingerprint consists of several features, such as the cooling rate of the component surface or the melt pool’s surface geometry, which are determined using »machine-learning« concepts from multispectral process image data. The algorithms employed can be used, for example, to classify welds and make corresponding manufacturing processes more cost-effective through real-time control.

Project Results 2017

Project Results 2016

Here you will find a selection of current collaborative projects

“ADIR”

Next generation urban mining - Automated disassembly, separation and recovery of valuable materials from electronic equipment

“ComMUnion”

Net-shape joining technology to manufacture 3D multi-materials components based on metal alloys and thermoplastic composites

“EVEREST”

Development of Intelligent Process and System Technology for Extreme High-Speed Laser Material Deposition

“futureAM”

Next Generation Additive Manufacturing

“INSPIRE”

Interferometric Distance Sensor System with Autonomous Subsystems for High-Precision Inline Measurements to Control Automated Manufacturing Processes

“NeuGenWälz”

New Materials for the Additive Manufacturing of Roller Bearings

“ProLMD”

Process and System Technology for Hybrid Production of Large Components with Laser Material Deposition (LMD)

“TriboLas-3D”

Process Development for the Laser-Based Production of Site-Selective Tribological Layer Systems on 3D Surfaces

“ultraSURFACE”

Ultra Dynamic Optical Systems for High Throughput Laser Surface Processing

Contact

Dipl.-Ing. Hans-Dieter Hoffmann

“Lasers and Optics”

 

Telephone +49 241 8906-206
-> Send E-Mail

 

Dr.-Ing. Arnold Gillner

“Ablation and Joining”

 

Telephone +49 241 8906-148
-> Send E-Mail

Prof. Dr.-Ing. Johannes Henrich Schleifenbaum

“Additive Manufacturing
and Functional Layers”

 

Telephone +49 241 8906-398
-> Send E-Mail

Prof. Dr. rer. nat. Reinhard Noll

“Measurement Technology
and EUV Sources”

 

Telephone +49 241 8906-138
-> Send E-Mail