TY - JOUR AB - 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. AU - Ostermann, Moritz AU - Grenz, Julian AU - Triebus, Marcel AU - Cerdas, Felipe AU - Marten, Thorsten AU - Tröster, Thomas AU - Herrmann, Christoph ID - 43464 IS - 8 JF - Energies KW - Life Cycle Engineering KW - Life Cycle Assessment KW - Lightweight Design KW - Prospective LCA KW - Future-oriented LCA KW - Energy System KW - Material production KW - Sustainable production SN - 1996-1073 TI - Integrating Prospective Scenarios in Life Cycle Engineering: Case Study of Lightweight Structures VL - 16 ER - TY - CONF AB - 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. AU - Lückenkötter, Julian AU - Leimbach, J.P. AU - Stallmeister, Tim AU - Marten, Thorsten AU - Tröster, Thomas ID - 44154 KW - Compression Molding KW - Fiber Content KW - Process Development KW - Lightweight Design T2 - Materials Research Proceedings TI - Feasibility Study of Compression Molding for Large Reinforcement Structures in the Commercial Vehicle Sector VL - 28 ER - TY - CONF AB - 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. AU - Ostermann, Moritz AU - Behm, Jonathan AU - Marten, Thorsten AU - Tröster, Thomas AU - Weyer, Johannes AU - Cepera, Kay AU - Adelt, Fabian ED - Proff, Heike ID - 44502 SN - 9783658394370 T2 - Towards the New Normal in Mobility TI - Individualization of Public Transport – Integration of Technical and Social Dimensions of Sustainable Mobility ER - TY - JOUR AB - (1) This work answers the question of whether and to what extent there is a significant difference in mechanical properties when different additive manufacturing processes are applied to the material 1.2709. The Laser-Powder-Bed-Fusion (L-PBF) and Laser-Metal-Deposition (LMD) processes are considered, as they differ fundamentally in the way a part is manufactured. (2) Known process parameters for low-porosity parts were used to fabricate tensile strength specimens. Half of the specimens were heat-treated, and all specimens were tested for mechanical properties in a quasi-static tensile test. In addition, the material hardness was determined. (3) It was found that, firstly, heat treatment resulted in a sharp increase in mechanical properties such as hardness, elastic modulus, yield strength and ultimate strength. In addition to the increase in these properties, the elongation at break also decreases significantly after heat treatment. The choice of process, on the other hand, does not give either process a clear advantage in terms of mechanical properties but shows that it is necessary to consider the essential mechanical properties for a desired application. AU - Gnaase, Stefan AU - Niggemeyer, Dennis AU - Lehnert, Dennis AU - Bödger, Christian AU - Tröster, Thomas ID - 37200 IS - 2 JF - Crystals KW - Inorganic Chemistry KW - Condensed Matter Physics KW - General Materials Science KW - General Chemical Engineering SN - 2073-4352 TI - Comparative Study of the Influence of Heat Treatment and Additive Manufacturing Process (LMD & L-PBF) on the Mechanical Properties of Specimens Manufactured from 1.2709 VL - 13 ER - TY - JOUR AB - 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. AU - Grenz, Julian AU - Ostermann, Moritz AU - Käsewieter, Karoline AU - Cerdas, Felipe AU - Marten, Thorsten AU - Herrmann, Christoph AU - Tröster, Thomas ID - 45782 IS - 13 JF - Sustainability KW - prospective LCA KW - life cycle engineering (LCE) KW - lightweight design KW - automotive components KW - body parts KW - circular economy KW - steel KW - aluminum KW - hybrid materials KW - fiber metal laminates SN - 2071-1050 TI - Integrating Prospective LCA in the Development of Automotive Components VL - 15 ER - TY - GEN AU - Ostermann, Moritz AU - Behm, Jonathan AU - Marten, Thorsten AU - Tröster, Thomas ID - 42459 T2 - WerkstoffPlus Auto 13. Fachtagung für neue Fahrzeug- und Werkstoffkonzepte TI - NeMo.bil - Dekarbonisierung des Verkehrs mithilfe von Leichtbau-Fahrzeugschwärmen ER - TY - JOUR AU - Wu, Shuang AU - Delp, Alexander AU - Freund, Jonathan AU - Walther, Frank AU - Haubrich, Jan AU - Löbbecke, Miriam AU - Tröster, Thomas ID - 46495 JF - The Journal of Adhesion KW - Materials Chemistry KW - Surfaces KW - Coatings and Films KW - Surfaces and Interfaces KW - Mechanics of Materials KW - General Chemistry SN - 0021-8464 TI - Adhesion properties of the hybrid system made of laser-structured aluminium EN AW 6082 and CFRP by co-bonding-pressing process ER - TY - JOUR AU - Freund, Jonathan AU - Löbbecke, Miriam AU - Delp, Alexander AU - Walther, Frank AU - Wu, Shuang AU - Tröster, Thomas AU - Haubrich, Jan ID - 46494 JF - The Journal of Adhesion KW - Materials Chemistry KW - Surfaces KW - Coatings and Films KW - Surfaces and Interfaces KW - Mechanics of Materials KW - General Chemistry SN - 0021-8464 TI - Relationship between laser-generated micro- and nanostructures and the long-term stability of bonded epoxy-aluminum joints ER - TY - CONF AU - Wu, Shuang AU - Freund, Jonathan AU - Delp, Alexander AU - Haubrich, Jan AU - Löbbecke, Miriam AU - Walther, Frank AU - Tröster, Thomas ID - 48597 TI - Intrinsic forming of hybrid parts made of laser-structured aluminium sheet and CFRP-Prepreg ER - TY - CHAP AU - Akbulut Irmak, Emine Fulya AU - Hanses, Hendrik AU - Horwath, Ilona AU - Tröster, Thomas ID - 48643 SN - 2703-1543 T2 - Climate Protection, Resource Efficiency, and Sustainable Engineering TI - Case Study III: Challenges of lightweight design, vehicles, and rescuers ER - TY - THES AB - Hybride Bauteile, welche aus Werkstoffen mit hohen spezifischen Festigkeiten bestehen, können zu einem signifikanten Leichtbau im Automobil beitragen. Diese Arbeit erforscht die hybride Kombination von pressgehärtetem Stahl und kohlenstofffaserverstärktem Kunststoff. Ausgehend von einer Analyse bestehender Karosseriestrukturen erfolgt ein Konzept für eine hybride B-Säule. Das Potential zur Gewichtsreduzierung durch das hybride Bauteilkonzept wurde dabei zu 57 % identifiziert, welches jedoch nur bei Sicherstellung einer intakten Grenzfläche erreicht wird. Zur Erlangung der Grenzflächenfestigkeit bei charakteristischen Belastungsprofilen wurde ein Verfahren zur Einbringung makroskopischer Formschlusselemente im Presshärteprozess entwickelt. Durch diese Formschlusselemente wird eine Steigerung der Scherfestigkeit der hybriden Komponenten von über 300 % erreicht. Die gewonnenen Erkenntnisse werden abschließend zur Auslegung einer hybriden B-Säule angewendet. AU - Triebus, Marcel ID - 49155 TI - Belastungsgerechte Auslegung automobiler Leichtbaustrukturen aus pressgehärtetem Stahl und kohlenstofffaserverstärktem Kunststoff ER - TY - CONF AU - Lückenkötter, Julian AU - Aydin, Simon AU - Marten, Thorsten AU - Tröster, Thomas ID - 48586 TI - Analysis and Optimization of Joint Formation in Hybrid Compression Molding ER - TY - THES AB - Hybridstrukturen bieten bei Anwendungen mit Biegebeanspruchung ein großes Leichtbaupotenzial, erfordern jedoch komplexe und zum Teil mehrschrittige Fertigungsverfahren. In dieser Arbeit wird ein Verfahren entwickelt, das auf Basis des Fließpressprozesses biegebelastbare Hybridbalken in einem Schritt herstellt. Dazu wird ein Versuchsträger entwickelt, der die Komplexität von Realbauteilen abbildet und für zerstörende sowie zerstörungsfreie Charakterisierungsmethoden geeignet ist. Der Versuchsträger besteht aus einer funktionalisierten Kernstruktur aus Glasfasermattenverstärktem Polypropylen und äußeren Metallgurten aus Stahl- und Aluminiumlegierungen, die mit einem Haftvermittlerfilm versehen sind. Anhand des Versuchsträgers wird ein Fließpresswerkzeug und eine instrumentierte Fertigungsanlage entwickelt, mit der die Hybridstrukturen prototypisch hergestellt werden. Zur Prozessoptimierung wird die Verbindung mechanisch und optisch auf Probenebene analysiert. Weiterhin erfolgen Bauteiluntersuchungen anhand von Dreipunktbiegetests, mit denen das strukturelle Verhalten der Hybridbalken charakterisiert wird. Es wird festgestellt, dass sich mit dem einstufigen Fließpressverfahren sehr gute Verbundfestigkeiten erzielen lassen. Die Temperatur- und Druckführung weisen dabei einen großen Einfluss auf das Ergebnis auf. Anhand der Bauteiluntersuchungen wird bestätigt, dass mit dem entwickelten Verfahren Hybridbalken in nur einem Schritt gefertigt werden können, die vergleichbare mechanische Eigenschaften zu Hybridstrukturkonzepten aus mehrschrittigen Fertigungsverfahren aufweisen. AU - Stallmeister, Tim ID - 50448 TI - Verfahrensentwicklung zur einstufigen Herstellung von biegebelastbaren Hybridstrukturen im Fließpressprozess ER - TY - GEN AU - Knorr, Lukas AU - Jungeilges, André AU - Pfeifer, Florian AU - Burmeister, Sascha Christian AU - Meschede, Henning ID - 48335 TI - Regenerative Energien für einen effizienten Betrieb von Presshärtelinien ER - TY - GEN AU - Jungeilges, André ID - 49106 TI - Possibilities of Sustainable Heating Methods for Press Hardening Processes ER - TY - CONF AB - Bei der Herstellung materialeffizienter Bauteile aus presshärtbaren Stählen für den Leichtbau sind nachhaltige und energieschonende Produktionsverfahren ein wichtiger Bestandteil der industriellen Prozesskette. Mittels direkter resistiver Erwärmung basierend auf dem Jouleschen Gesetz können Platinen energieeffizient, flexibel, bedarfsgerecht und „On Demand“ erwärmt werden. Restriktionen des Verfahrens ergaben sich bisher aus den realisierbaren Platinengeometrien. Ferner fehlten serientaugliche Konzepte zur automatisierten Fertigung resistiv erwärmter Bauteile. Durch ein neuentwickeltes Verfahren wird die resistive Schnellerwärmung von komplexen, umformtechnisch optimierten Bauteilen ermöglicht, wodurch eine vielfältige industrielle Nutzung realisiert werden kann. Aus diesem Grund wurde das neue Verfahren zur energieeffizienten Erwärmung anhand des Presshärteprozesses untersucht. Dazu wurde das Verfahren zunächst auf Probenebene verifiziert und innovative Erwärmungsstrategien durch die Modifizierung des Stromflusses untersucht. Weiterhin wurden prozessnahe Umformversuche durchgeführt und analysiert. Der Fokus der Untersuchungen lag auf der Prozesstechnik insbesondere der Homogenität der Temperaturverteilung sowie den erzeugten mechanischen Eigenschaften der Bauteile. AU - Kaiser, Maximilian Alexander AU - Reitz, Alexander AU - Konrad, Stefan AU - Meyer, Thomas AU - Marten, Thorsten AU - Tröster, Thomas ED - Merklein, Marion ID - 49436 KW - Presshärten KW - resistive Schnellerwärmung KW - Energieeffizienz SN - 978-3-00-077160-6 T2 - Workshop Warmblechumformung TI - Untersuchung energieeffizienter und serientauglicher Erwärmungsstrategien mittels resistiver Erwärmung für den Presshärteprozess VL - 18 ER - TY - CONF AB - The nickel-based alloy Inconel 718, which is used in aerospace technology, poses a great challenge to conventional machining due to its high strain hardening and toughness. Here, the laser powder bed fusion process (LPBF) offers an alternative with potential savings if sufficiently high productivity can be achieved. Based on the parameter study carried out, starting from the SLM Solutions standard parameters for the manufacturing of components, exposure parameters could be developed to realize manufacturing with 120 μm and 150 μm layer thickness, with almost the same geometric accuracy. For this purpose, the process parameters of laser power, focus diameter, hatch distance and scan speed were varied. The negative defocusing of the laser showed a positive effect on the density of the parts, realizing densities ≥ 99.94 %, with high dimensional stability and good mechanical properties. Considering the reduced manufacturing time of up to 61 %, a significant increase in productivity was achieved. AU - Bödger, Christian AU - Gnaase, Stefan AU - Lehnert, Dennis AU - Tröster, Thomas ID - 50742 T2 - Proceedings of the 34th Annual International Solid Freeform Fabrication Symposium – An Additive Manufacturing Conference TI - Investigation of the influence of process parameters on productivity in the LPBF process for the material Inconel 718 ER - TY - THES AB - The importance of fiber-reinforced plastics for lightweight construction applications is steadily increasing due to their outstanding weight-specific property values. However, a decisive disadvantage of these composite materials has so far been the high material and process costs, which is why fiber-reinforced plastics are almost exclusively used in small to medium-sized series. Optimization of manufacturing methods is of great importance to reduce the production cost. In this study, two concepts are proposed that can optimize vacuum assisted light resin transfer molding (VA-LRTM) further, leading to a possibility of fully automatic process. Conventional VA-LRTM methods are used to produce complex fiber-reinforced plastics (FRP) and hybrid components. Traditional molds used to produce components via VA-LRTM are sealed using polymer materials to prevent the leakage of matrix system. The seals undergo tremendous amounts of thermal, chemical, and mechanical loadings. Thus, sealings must be replaced in short intervals. In the current study, a concept where sealing is achieved by accelerating the curing of matrix system itself with the help of heating elements and catalysts resulting in a self-sealing approach is proposed. Another concern is mold surface contamination during component production. To address this, a modified automatic cleaning technique based on ultrasonic cleaning was proposed which can be integrated into the production line with minimum modification. Both the proposed concepts were validated and optimized using experiments, simulations, and analytical approaches by producing metal-FRP hybrid shafts. AU - Chalicheemalapalli Jayasankar, Deviprasad ID - 50449 KW - fiber-reinforced plastics KW - resin transfer molding KW - composites TI - Advances In RTM Manufacturing Of Metal-FRP Hybrids By Self-Sealing And In-Mold Cleaning Techniques ER - TY - GEN AU - Chalicheemalapalli Jayasankar, Deviprasad AU - Stallmeister, Tim AU - Lückenkötter, Julian AU - Tröster, Thomas ID - 45831 KW - Compression Molding KW - Glass Mat Thermoplastics KW - Hybrid Brake Pedal TI - In-Mold Assembly of Hybrid GMT-Steel Brake Pedals by Compression Molding ER - TY - JOUR AU - Tuzgel, Firat AU - Akbulut Irmak, Emine Fulya AU - Guzel, Erkan AU - Yucesoy, Atacan AU - Sahin, Selim AU - Tasdemirci, Alper AU - Guden, Mustafa ID - 30894 JF - Thin-Walled Structures KW - Mechanical Engineering KW - Building and Construction KW - Civil and Structural Engineering SN - 0263-8231 TI - Testing and modeling blast loading of a sandwich structure cored with a bio-inspired (balanus) core VL - 175 ER -