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 -