@inproceedings{55638,
  abstract     = {{<jats:p>Abstract. Traditionally, joints are cylindrical and rotationally symmetric. In the present study, non-rotationally symmetric joints are used for joining steel and Glass mat-reinforced thermoplastic sheets (GMT). In addition, the study also analyzes the impact of non-rotational symmetric joint rotation on the load-bearing capacity. Single lap joint specimens were fabricated using the In-Mold assembly technique for joining steel sheets with GMT. Tensile shear tests were performed on different orientations of the joint geometry, and it was observed that changing the joint orientation influences the load-bearing capacity. The joints are constitutively modeled using beam elements and the influence of joint rotation on load distribution is examined through a static simulation study. </jats:p>}},
  author       = {{Devulapally, Deekshith Reddy and Martin, Sven and Tröster, Thomas}},
  booktitle    = {{Materials Research Proceedings}},
  issn         = {{2474-395X}},
  publisher    = {{Materials Research Forum LLC}},
  title        = {{{Non-rotationally symmetric joints – Mechanisms and load bearing capacity}}},
  doi          = {{10.21741/9781644903131-183}},
  year         = {{2024}},
}

@inproceedings{57202,
  author       = {{Ostermann, Moritz and Marten, Thorsten and Tröster, Thomas}},
  booktitle    = {{16th Biennial International Conference on EcoBalance}},
  keywords     = {{Life Cycle Sustainability Assessment, Prospective Life Cycle Assessment, Life Cycle Engineering, On-Demand Mobility, Mobility Services}},
  location     = {{Sendai, Japan}},
  title        = {{{Prospective Life Cycle Assessment of Lightweight Structures in Vehicles for On-Demand Mobility Systems}}},
  year         = {{2024}},
}

@inproceedings{57537,
  author       = {{Ostermann, Moritz and Marten, Thorsten and Tröster, Thomas}},
  booktitle    = {{Sustainability in Product and Production Engineering}},
  location     = {{Bad Nauheim}},
  publisher    = {{Automotive Circle}},
  title        = {{{Scenario-based life cycle assessment of vehicle lightweight structures}}},
  year         = {{2024}},
}

@article{58381,
  author       = {{Suresh, Keenatampalle and Kesavulu, C.R. and Chalicheemalapalli Jayasankar, Deviprasad and Pecharapa, Wisanu and Kagola, Upendra Kumar and Tröster, Thomas and Jayasankar, C.K.}},
  issn         = {{0022-2313}},
  journal      = {{Journal of Luminescence}},
  publisher    = {{Elsevier BV}},
  title        = {{{Stokes and anti-Stokes emission characteristics of Er3+/Yb3+ co-doped zinc tellurite glasses under 377 and 1550 nm excitations for solar energy conversion application}}},
  doi          = {{10.1016/j.jlumin.2024.120948}},
  volume       = {{277}},
  year         = {{2024}},
}

@article{57699,
  abstract     = {{<jats:p>The optimization of process parameters in powder Directed Energy Deposition (DED) is essential for achieving consistent, high-quality bead geometries, which directly influence the performance and structural integrity of fabricated components. As a subset of additive manufacturing (AM), the DED process, also referred to as laser metal deposition (LMD), enables precise, layer-by-layer material deposition, making it highly suitable for complex geometries and part repair applications. Critical parameters, such as the laser power, feed rate, powder mass flow, and substrate temperature govern the deposition process, impacting the bead height, width, contact angle, and dilution. Inconsistent control over these variables can lead to defects, such as poor bonding, dimensional inaccuracies, and material weaknesses, ultimately compromising the final product. This paper investigates the effects of various process parameters, specifically the substrate temperature, on bead track geometry in DED processes for stainless steel (1.4404). A specialized experimental setup, integrated within a DED machine, facilitates the controlled thermal conditioning of sample sheets. Using Design of Experiments (DoE) methods, individual bead marks are generated and analyzed to assess geometric characteristics. Regression models, including both linear and quadratic approaches, are constructed to predict machine parameters for achieving the desired bead geometry at different substrate temperatures. Validation experiments confirm the accuracy and reliability of the models, particularly in predicting the bead height, bead width, and contact angle across a broad range of substrate temperatures. However, the models demonstrated limitations in accurately predicting dilution, indicating the need for further refinement. Despite some deviations in measured values, successful fabrication is achieved, demonstrating robust bonding between the bead and substrate. The developed models offer insights into optimizing DED process parameters to achieve desired bead characteristics, advancing the precision and reliability of additive manufacturing technology. Future work will focus on refining the regression models to improve predictions, particularly for dilution, and further investigate non-linear interactions between process variables.</jats:p>}},
  author       = {{Chalicheemalapalli Jayasankar, Deviprasad and Gnaase, Stefan and Lehnert, Dennis and Walter, Artur and Rohling, Robin and Tröster, Thomas}},
  issn         = {{2075-4701}},
  journal      = {{Metals}},
  keywords     = {{additive manufacturing, direct energy deposition, laser metal deposition}},
  number       = {{12}},
  publisher    = {{MDPI AG}},
  title        = {{{Effect of Substrate Temperature on Bead Track Geometry of 316L in Directed Energy Deposition: Investigation and Regression Modeling}}},
  doi          = {{10.3390/met14121353}},
  volume       = {{14}},
  year         = {{2024}},
}

@article{56089,
  abstract     = {{<jats:p>Additive manufacturing (AM) technologies enable near-net-shape designs and demand-oriented material usage, which significantly minimizes waste. This points to a substantial opportunity for further optimization in material savings and process design. The current study delves into the advancement of sustainable manufacturing practices in the automotive industry, emphasizing the crucial role of lightweight construction concepts and AM technologies in enhancing resource efficiency and reducing greenhouse gas emissions. By exploring the integration of novel AM techniques such as selective laser melting (SLM) and laser metal deposition (LMD), the study aims to overcome existing limitations like slow build-up rates and limited component resolution. The study’s core objective revolves around the development and validation of a continuous process chain that synergizes different AM routes. In the current study, the continuous process chain for DMG MORI Lasertec 65 3D’s LMD system and the DMG MORI Lasertec 30 3D’s was demonstrated using 316L and 1.2709 steel materials. This integrated approach is designed to significantly curtail process times and minimize component costs, thus suggesting an industry-oriented process chain for future manufacturing paradigms. Additionally, the research investigates the production and material behavior of components under varying manufacturing processes, material combinations, and boundary layer materials. The culmination of this study is the validation of the proposed process route through a technology demonstrator, assessing its scalability and setting a benchmark for resource-efficient manufacturing in the automotive sector.</jats:p>}},
  author       = {{Chalicheemalapalli Jayasankar, Deviprasad and Gnaase, Stefan and Kaiser, Maximilian Alexander and Lehnert, Dennis and Tröster, Thomas}},
  issn         = {{2075-4701}},
  journal      = {{Metals}},
  keywords     = {{additive manufacturing (AM), selective laser melting (SLM), laser metal deposition (LMD), hybrid manufacturing, process optimization, 316L, 1.2709}},
  number       = {{7}},
  publisher    = {{MDPI AG}},
  title        = {{{Advancements in Hybrid Additive Manufacturing: Integrating SLM and LMD for High-Performance Applications}}},
  doi          = {{10.3390/met14070772}},
  volume       = {{14}},
  year         = {{2024}},
}

@article{55743,
  abstract     = {{The use of hybrid materials as a combination of fibre-reinforced plastic (FRP) and metal is of great interest in order to meet the increasing demands for sustainability, efficiency, and emission reduction based on the principle of lightweight design. These two components can therefore be joined using the intrinsic joining technique, which is formed by curing the matrix of the FRP component. In this study, for the hybrid joint, unidirectionally pre-impregnated semi-finished products (prepregs) with duromer matrix resin and micro-alloyed HC340LA steel were used. In order to conduct a detailed investigation, the damage mechanisms of intrinsically produced fibre metal laminates (FMLs), a new clamping device, and a novel pressing tool were designed and put into operation. The prepregs were prestressed by applying a preloading force using a specially designed prestressing frame. Hybrid specimens were then produced and subjected to nanoindentation and a shear tensile test. In particular, the effect of the residual stress state by varying the defined prestressing force on the damage mechanisms was studied. The results showed that no fracture patterns occurred in the interface of the specimens without preloading as a result of curing at 120 °C, whereas specimens with preloading failed at the boundary layer in the tensile range. Nevertheless, all specimens cured at 160 °C failed at the boundary layer in the tensile range. Furthermore, it was proven that the force and displacement of the preloaded specimens were promisingly higher than those of the unpreloaded specimens.}},
  author       = {{Irmak, Hayrettin and Tinkloh, Steffen Rainer and Marten, Thorsten and Tröster, Thomas}},
  issn         = {{2504-477X}},
  journal      = {{Journal of Composites Science}},
  keywords     = {{CFRP, prestressing, fibre metal laminate, interface, prepreg, shear tensile test}},
  number       = {{8}},
  publisher    = {{MDPI AG}},
  title        = {{{Development of a Tool Concept for Prestressed Fibre Metal Laminates and Their Effect on Interface Failure}}},
  doi          = {{10.3390/jcs8080316}},
  volume       = {{8}},
  year         = {{2024}},
}

@inbook{48643,
  author       = {{Akbulut Irmak, Emine Fulya and Hanses, Hendrik and Horwath, Ilona and Tröster, Thomas}},
  booktitle    = {{Climate Protection, Resource Efficiency, and Sustainable Engineering}},
  isbn         = {{9783837663778}},
  issn         = {{2703-1543}},
  publisher    = {{transcript Verlag}},
  title        = {{{Case Study III: Challenges of lightweight design, vehicles, and rescuers}}},
  doi          = {{10.14361/9783839463772-006}},
  year         = {{2023}},
}

@inproceedings{48586,
  author       = {{Lückenkötter, Julian and Aydin, Simon and Marten, Thorsten and Tröster, Thomas}},
  location     = {{Belfast}},
  title        = {{{Analysis and Optimization of Joint Formation in Hybrid Compression Molding}}},
  year         = {{2023}},
}

@inproceedings{45831,
  author       = {{Chalicheemalapalli Jayasankar, Deviprasad and Stallmeister, Tim and Lückenkötter, Julian and Tröster, Thomas}},
  keywords     = {{Compression Molding, Glass Mat Thermoplastics, Hybrid Brake Pedal}},
  location     = {{Trondheim, Norway }},
  title        = {{{In-Mold Assembly of Hybrid GMT-Steel Brake Pedals by Compression Molding}}},
  year         = {{2023}},
}

@inbook{44502,
  abstract     = {{In order to follow the 1.5 degree path of the Paris Climate Agreement, drastic greenhouse gas reduction measures are needed in the transport sector. The potential of public transport and new mobility services to reduce transport-related greenhouse gas emissions cannot yet be fully exploited, especially in rural regions. This paper presents the concept of an innovative mobility system, called NeMo.bil, that intends to fill the gap between individual and public transport to create a demand-oriented and sustainable mobility offer. The concept is based on convoy formation of autonomously driving lightweight vehicles serving the first and last mile and a larger towing vehicle carrying enough power and energy to move the convoy over longer distances at higher speeds. This combination of two different vehicles, intelligently controlled by a digital ecosystem, aims to significantly increasing energy, resource and cost efficiency. Based on an analysis of previous approaches for innovative mobility solutions, the concept is derived from a technical and sociological perspective and its potential for reducing energy demand is calculated.}},
  author       = {{Ostermann, Moritz and Behm, Jonathan and Marten, Thorsten and Tröster, Thomas and Weyer, Johannes and Cepera, Kay and Adelt, Fabian}},
  booktitle    = {{Towards the New Normal in Mobility}},
  editor       = {{Proff, Heike}},
  isbn         = {{9783658394370}},
  location     = {{Duisburg}},
  publisher    = {{Springer Fachmedien Wiesbaden}},
  title        = {{{Individualization of Public Transport – Integration of Technical and Social Dimensions of Sustainable Mobility}}},
  doi          = {{10.1007/978-3-658-39438-7_25}},
  year         = {{2023}},
}

@article{43464,
  abstract     = {{<jats:p>Lightweight design is a common approach to reduce energy demand in the use stage of vehicles. The production of lightweight materials is usually associated with an increase in energy demand, so the environmental impacts of lightweight structures need to be assessed holistically using a life cycle assessment. To estimate the life cycle environmental impacts of a product in its developmental stage, for example, by life cycle engineering, future changes in relevant influencing factors must be considered. Prospective life cycle assessment provides methods for integrating future scenarios into life cycle assessment studies. However, approaches for integrating prospective life cycle assessment into product development are limited. The objective of this work is to provide the methodological foundation for integrating future scenarios of relevant influencing factors in the development of lightweight structures. The applicability of the novel methodology is demonstrated by a case study of a structural component in a steel, aluminium, and hybrid design. The results show that appropriate decarbonisation measures can reduce the life cycle greenhouse gas emissions by up to 95 percent until 2050. We also found that shifts in the environmentally optimal design are possible in future scenarios. Therefore, the methodology and data provided contribute to improved decision-making in product development.</jats:p>}},
  author       = {{Ostermann, Moritz and Grenz, Julian and Triebus, Marcel and Cerdas, Felipe and Marten, Thorsten and Tröster, Thomas and Herrmann, Christoph}},
  issn         = {{1996-1073}},
  journal      = {{Energies}},
  keywords     = {{Life Cycle Engineering, Life Cycle Assessment, Lightweight Design, Prospective LCA, Future-oriented LCA, Energy System, Material production, Sustainable production}},
  number       = {{8}},
  publisher    = {{MDPI AG}},
  title        = {{{Integrating Prospective Scenarios in Life Cycle Engineering: Case Study of Lightweight Structures}}},
  doi          = {{10.3390/en16083371}},
  volume       = {{16}},
  year         = {{2023}},
}

@inproceedings{44154,
  abstract     = {{<jats:p>Abstract. Due to an increasing volume of shipments, there is a significant need for more delivery vehicles. One approach to reduce the associated increase in carbon dioxide (CO2) emissions is a new light weight design approach involving the substitution of conventional materials with glass fiber mat-reinforced thermoplastics (GMT) based on polypropylene (PP). The application of GMT by compression molding is a widely used process in the automotive industry. However, application in the commercial vehicle sector requires much larger dimensions, making it necessary to clarify whether the manufacturing process and material are suitable for semi-structural applications on this scale. To find this out, two replacement geometries are abstracted in this study and manufactured by varying the main manufacturing parameters. The feasibility can be demonstrated by recording and analyzing the resulting process variables and measuring the formed fiber distribution. At the end of the paper, recommendations are given for the production of GMT structures on the scale of commercial vehicles. </jats:p>}},
  author       = {{Lückenkötter, Julian and Leimbach, J.P. and Stallmeister, Tim and Marten, Thorsten and Tröster, Thomas}},
  booktitle    = {{Materials Research Proceedings}},
  issn         = {{978-1-64490-247-9}},
  keywords     = {{Compression Molding, Fiber Content, Process Development, Lightweight Design}},
  location     = {{Krakow, Poland}},
  pages        = {{249--258}},
  publisher    = {{Materials Research Forum LLC}},
  title        = {{{Feasibility Study of Compression Molding for Large Reinforcement Structures in the Commercial Vehicle Sector}}},
  doi          = {{10.21741/9781644902479-27}},
  volume       = {{28}},
  year         = {{2023}},
}

@article{45782,
  abstract     = {{<jats:p>The development of automotive components with reduced greenhouse gas (GHG) emissions is needed to reduce overall vehicle emissions. Life Cycle Engineering (LCE) based on Life Cycle Assessment (LCA) supports this by providing holistic information and improvement potentials regarding eco-efficient products. Key factors influencing LCAs of automotive components, such as material production, will change in the future. First approaches for integrating future scenarios for these key factors into LCE already exist, but they only consider a limited number of parameters and scenarios. This work aims to develop a method that can be practically applied in the industry for integrating prospective LCAs (pLCA) into the LCE of automotive components, considering relevant parameters and consistent scenarios. Therefore, pLCA methods are further developed to investigate the influence of future scenarios on the GHG emissions of automotive components. The practical application is demonstrated for a vehicle component with different design options. This paper shows that different development paths of the foreground and background system can shift the ecological optimum of design alternatives. Therefore, future pathways of relevant parameters must be considered comprehensively to reduce GHG emissions of future vehicles. This work contributes to the methodological and practical integration of pLCA into automotive development processes and provides quantitative results.</jats:p>}},
  author       = {{Grenz, Julian and Ostermann, Moritz and Käsewieter, Karoline and Cerdas, Felipe and Marten, Thorsten and Herrmann, Christoph and Tröster, Thomas}},
  issn         = {{2071-1050}},
  journal      = {{Sustainability}},
  keywords     = {{prospective LCA, life cycle engineering (LCE), lightweight design, automotive components, body parts, circular economy, steel, aluminum, hybrid materials, fiber metal laminates}},
  number       = {{13}},
  publisher    = {{MDPI AG}},
  title        = {{{Integrating Prospective LCA in the Development of Automotive Components}}},
  doi          = {{10.3390/su151310041}},
  volume       = {{15}},
  year         = {{2023}},
}

@inproceedings{42459,
  author       = {{Ostermann, Moritz and Behm, Jonathan and Marten, Thorsten and Tröster, Thomas}},
  booktitle    = {{WerkstoffPlus Auto 13. Fachtagung für neue Fahrzeug- und Werkstoffkonzepte}},
  location     = {{Stuttgart}},
  title        = {{{NeMo.bil - Dekarbonisierung des Verkehrs mithilfe von Leichtbau-Fahrzeugschwärmen}}},
  year         = {{2023}},
}

@article{46494,
  abstract     = {{To improve the mechanical performance and to address current shortcomings of adhesive bonds such as bond degradation due to aging, a pulsed laser surface pretreatment of the metal surfaces of aluminum AW 6082-T6 joints with epoxy adhesive E320 is investigated. The surface treatment of the specimens resulted in increased single-lap shear (SLS) strengths before and after hydrothermal aging in 80°C hot water compared to nonpretreated reference specimens. In order to reveal the correlations of laser parameters, resulting surface morphologies and the SLS strength, differently laser pretreated surfaces were characterized at the micro- and nanoscale using optical and scanning electron microscopies. The surface enlargement was quantified with a digital image analysis of cross-sections prepared from the joint interfaces. An analysis of variances (ANOVA) of the SLS results indicated that the laser parameters power and pulse frequency were most critical for obtaining high SLS strengths. Pretreated joint surfaces with a high micro- and nano-surface enlargement and deep solidification structures provide high SLS strengths of up to 50 MPa and almost negligible aging losses of merely 4%. Undercut structures on the pretreated surfaces were found to be beneficial for the mechanical and aging properties when only limited micro- and nanostructuring was applied.}},
  author       = {{Freund, Jonathan and Löbbecke, Miriam and Delp, Alexander and Walther, Frank and Wu, Shuang and Tröster, Thomas and Haubrich, Jan}},
  issn         = {{0021-8464}},
  journal      = {{The Journal of Adhesion}},
  keywords     = {{Materials Chemistry, Surfaces, Coatings and Films, Surfaces and Interfaces, Mechanics of Materials, General Chemistry}},
  pages        = {{1--31}},
  publisher    = {{Informa UK Limited}},
  title        = {{{Relationship between laser-generated micro- and nanostructures and the long-term stability of bonded epoxy-aluminum joints}}},
  doi          = {{10.1080/00218464.2023.2223475}},
  year         = {{2023}},
}

@article{55760,
  abstract     = {{The transferability of structure–property relationships for laser-pretreated metal adhesive joints to laser-pretreated metal–carbon-fiber-reinforced plastic (CFRP) bonds was investigated. Single-lap shear tests were performed on hybrid AW 6082-T6–CFRP specimens pretreated with the same pulsed laser surface parameter sets on the metal surface as previously tested, AW 6082-T6–E320 metal adhesive joints. The fracture surfaces were characterized to determine the type of failure and elucidate differences and commonalities in the link between surface structures and single-lap shear strengths. Digital image analyses of the hybrid specimens’ fractured surfaces were used to quantify remaining CFRP fragments on the metallic joint side. The results indicate that high surface enlargements and the presence of undercut structures lead to single-lap shear strengths exceeding 40 MPa and 35 MPa for unaged and aged hybrid specimens, respectively. Whereas for the metal–polymer joints, the trend from high strength to weakly bonded specimens is largely continuous with the degree of surface structuring, hybrid metal–CFRP joints exhibit a drastic drop in joint performance after aging if the laser-generated surface structures are less pronounced with low surface enlargements and crater depths. Surface features and hydrothermal aging determine whether the specimens fail cohesively or adhesively.</jats:p>}},
  author       = {{Freund, Jonathan and Lützenkirchen, Isabel and Löbbecke, Miriam and Delp, Alexander and Walther, Frank and Wu, Shuang and Tröster, Thomas and Haubrich, Jan}},
  issn         = {{2504-477X}},
  journal      = {{Journal of Composites Science}},
  number       = {{10}},
  publisher    = {{MDPI AG}},
  title        = {{{Transferability of the Structure–Property Relationships from Laser-Pretreated Metal–Polymer Joints to Aluminum–CFRP Hybrid Joints}}},
  doi          = {{10.3390/jcs7100427}},
  volume       = {{7}},
  year         = {{2023}},
}

@article{46495,
  abstract     = {{A parameter investigation for manufacturing a hybrid system through the prepreg pressing process was carried out within the scope of this work to achieve optimal adhesion properties. The hybrid specimen comprises an aluminium sheet of alloy EN AW 6082 in T6 condition and a thermoset Carbon Fibre Reinforced Plastics prepreg. The prepreg pressing process allows the curing reaction of epoxy resin and the joining process to occur simultaneously to avoid an additional bonding process step. The surface of the aluminium sheet was pretreated in advance using a pulsed Nd:YAG laser to enhance the bonding properties. In the first step, the shear edge tests investigated the adhesion properties achieved with different consolidation (temperature, time and pressure) and laser parameters. Then, 3-point bending tests were carried out to investigate the influence of the consolidation parameters on the mechanical properties of the Carbon Fibre Reinforced Plastics-laminate. In this way, the optimal parameter sets for manufacturing hybrid structures were determined.}},
  author       = {{Wu, Shuang and Delp, Alexander and Freund, Jonathan and Walther, Frank and Haubrich, Jan and Löbbecke, Miriam and Tröster, Thomas}},
  issn         = {{0021-8464}},
  journal      = {{The Journal of Adhesion}},
  keywords     = {{Materials Chemistry, Surfaces, Coatings and Films, Surfaces and Interfaces, Mechanics of Materials, General Chemistry}},
  pages        = {{1--29}},
  publisher    = {{Informa UK Limited}},
  title        = {{{Adhesion properties of the hybrid system made of laser-structured aluminium EN AW 6082 and CFRP by co-bonding-pressing process}}},
  doi          = {{10.1080/00218464.2023.2245758}},
  year         = {{2023}},
}

@inproceedings{48597,
  abstract     = {{This paper introduces an intrinsic manufacturing process of a hat profile made of laser-pretreated aluminium sheet of alloy EN AW-6082 in T6 condition and carbon fibre-reinforced plastic (CFRP) prepreg. The resin system used in combination with CFRP was epoxy resin (EP). Before manufacturing, the laser-pretreated aluminium sheet and CFRP prepreg were stacked to form a multi-layer composite, which was pressed simultaneously in one process step. The optimal CFRP layer structure was calculated in advance using the finite element method. During the forming process, the curing reaction and the joining of the aluminium sheet and CFRP prepreg will take place simultaneously. Thus, further joining techniques such as bonding and riveting could be saved, and a much more efficient process could be achieved. After manufacturing, shear-edge test was used to characterize the adhesion properties of the hybrid part.}},
  author       = {{Wu, Shuang and Freund, Jonathan and Delp, Alexander and Haubrich, Jan and Löbbecke, Miriam and Walther, Frank and Tröster, Thomas}},
  title        = {{{Intrinsic forming of hybrid parts made of laser-structured aluminium sheet and CFRP-Prepreg}}},
  year         = {{2023}},
}

@inproceedings{49436,
  author       = {{Kaiser, Maximilian Alexander and Reitz, Alexander and Konrad, Stefan and Meyer, Thomas and Marten, Thorsten and Tröster, Thomas}},
  booktitle    = {{Workshop Warmblechumformung}},
  editor       = {{Merklein, Marion}},
  isbn         = {{978-3-00-077160-6}},
  keywords     = {{Presshärten, resistive Schnellerwärmung, Energieeffizienz}},
  location     = {{Fürth}},
  pages        = {{99--118}},
  publisher    = {{Lehrstuhl für Fertigungstechnologie}},
  title        = {{{Untersuchung energieeffizienter und serientauglicher Erwärmungsstrategien mittels resistiver Erwärmung für den Presshärteprozess}}},
  volume       = {{18}},
  year         = {{2023}},
}