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Chair of Materials and Surface Engineering
Sustainable Materials and Processing
Chair of Materials and Surface Engineering 

Department of Sustainable Materials and Processing

Logo Nachhaltige Werkstoffe und -verarbeitung

Welcome to the Sustainable Materials and Processing department.

Our department carries out research and development into new materials and their processing methods. Underpinning this is the belief that modern, application-specific materials, combined with innovative processing methods, have the potential to make our society’s technologies sustainable. In our research and development, we always follow what are known as the ‘R-strategies’. In this way, we reduce the amount of material required and the energy consumed in processes, design products so that they can be recovered or recycled, or investigate ways of recovering secondary materials that are simple and tailored to the specific material. The research projects currently underway focus on steels, aluminium materials and metal matrix composites. To ensure comprehensive adaptation – that is, adaptation which takes into account material properties across different scales and under various application and processing conditions – we utilise not only analytical, characterisation and testing methods but also tools for materials and process simulation.

Under the tabs shown above, you will find more detailed information on our current and past projects, as well as our department’s publications.

Do you have any further questions, or is there anything we can do to help you with your work? If so, please feel free to contact us using the telephone number or email address below.

We look forward to a Let’s work together!

2026

Sub-project:
Recycling approaches for AMC, controlled particle distribution in castings, microstructural characterisation and optimisation
Department(s): Sustainable materials and manufacturing processes
Funding body: SAB
Funding reference number: 100768182
Duration: 2026–2028
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Project partners: thyssenkrupp Presta Dynamic Components, Chemnitz Metal Foundry GmbH, Bernstein Mechanical Manufacturing GmbH
Motivation & Objectives
The aim is to develop an electrically driven refrigerant compressor (eKMV) with increased energy efficiency, reduced weight and improved resource efficiency. To this end, a novel 9-kW compressor is being designed which, thanks to design simplifications, offers more cost-effective manufacturing and increased operational reliability. To extend the operating range and improve thermodynamic efficiency, a medium-pressure feed is being integrated into the compression process. This involves introducing refrigerant at an additional pressure level, thereby reducing the final compression temperature and increasing process stability. Another key focus of development is the replacement of conventional grey cast iron components with SiC-particle-reinforced aluminium matrix composites (AMC) for the cylinder housing.
As part of the collaborative project, a functional prototype and a technically optimised eKMV with integrated medium-pressure injection are being developed and tested. In addition, fundamental issues relating to materials and process development are being investigated. Furthermore, the reintroduction of machining swarf into the initial forming process is being investigated in order to develop recycling strategies for AMC materials and to assess their impact on the mechanical properties of the components. In addition, a sustainability assessment is being carried out using a cradle-to-cradle analysis.
Contact
Thomas Grund
Dr.-Ing.
Thomas Grund
Function: research associate
Phone: +49 (0)371 531 – 35390
Room: E01.103

2025

Sub-project:
Materials Production and Characterisation
Department(s): Sustainable materials and manufacturing processes
Funding body: SAB
Funding reference number: 100706092
Duration: 2025–2026
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Project partners: CMMC GmbH, Fraunhofer IWU Dresden, NRU GmbH, Benseler Sachsen GmbH & Co.KG
Motivation & Objectives
As part of the project, atomisation processes are being utilised in collaboration with industry and research partners to produce highly particle-reinforced aluminium matrix composite (AMC) powders and to process these into near-net-shape components using the LPBF process. The aim is to establish a systematic correlation between the feedstock, the atomisation process, the LPBF process parameters and the performance characteristics of the manufactured components. In addition, cost-effectiveness and component quality are being investigated in comparison with conventional casting processes.

By the end of the project, the scientific and technical foundations should be in place to manufacture high-quality AMC products and establish them on the market. The commercial project partners expect the development of new materials and products to expand their product portfolios.

Funding is provided from the European Regional Development Fund (ERDF) and from tax revenue, in accordance with the budget approved by the Saxon State Parliament.
Contact
Sarah J.  Hirsch
M.Sc.
Sarah J. Hirsch
Department: Sustainable materials and manufacturing processes
Function: research associate
Phone: +49 (0)371 531 – 36306
Room: E06.016

Department(s): Sustainable materials and manufacturing processes
Funding body: SAB
Funding reference number: 100748757
Duration: 2025–2027