Research

As part of a collaborative project funded by the Sächsische Aufbaubank (SAB) under the ERDF, the Chair of Materials and Surface Engineering at Chemnitz University of Technology, SITEC Industrietechnologie GmbH and CMMC GmbH are developing novel aluminium matrix composite(AMC) materials for laser beam cladding. The aim is to harness the potential of this class of materials – which are lightweight yet highly resistant to wear and corrosion – for additive manufacturing and coating processes.
AMC materials typically consist of aluminium alloys reinforced with 5–30 vol.% SiC particles, thereby exhibiting high mechanical and tribological performance combined with low density. The project aims to establish an end-to-end process chain for the production and processing of suitable AMC materials. This comprises the production of suitable AMC semi-finished products by CMMC GmbH, their conversion into high-quality powders via ultrasonic atomisation at Chemnitz University of Technology, and the processing of the composite powders into wear-and corrosion-resistant coatings by laser beam cladding at SITEC Industrietechnologie GmbH.
Through close collaboration between the project partners, fundamental relationships between material composition, process parameters, microstructure and the resulting properties of the AMC powders and coatings are being systematically investigated. On this basis, high-quality AMC composite powders, optimised for specific processes, are to be produced. The project thus strengthens the innovative capacity of additive manufacturing and coating technologies and contributes to the development of resource-efficient lightweight construction solutions in Saxony.

Electromagnetic forming (EMF) utilises the energy density of pulsed magnetic fields to apply force without contact and to carry out high-speed forming of highly electrically conductive workpieces. The high strain rates inherent to the process result in increased formability for many materials, enabling the forming of complex geometric features. Due to the combination of high mechanical strength and high electrical conductivity, copper alloys such as CuCrZr are now predominantly used as inductor materials in the EMU process. However, the resource-efficient and cost-effective design of the forming process is currently limited by the highly variable service life of the inductor. Despite numerous studies on electromagnetic forming, the mechanisms that lead to damage to the inductor—in some cases after just a few discharges—remain unclear to this day. In order to optimally design the inductor for the process and ensure the stability of its operational properties for a long service life, an understanding of the underlying process-structure-property relationships is necessary. As part of this project, the causal relationships between the inductor’s material microstructure—which directly influences its mechanical and electrical properties—its geometry and surface condition, as well as between the process parameters and the associated electro-thermo--mechanical stresses on the inductor, in order to gain a fundamental understanding of the damage processes and mechanisms occurring during EMU. Through the qualitative and quantitative evaluation of these influencing factors, conclusions can be drawn regarding the potential extension of the service life of the inductors, thereby ensuring a resource-efficient and cost-effective design of the forming process.

Increased environmental requirements for internal combustion engines and economic pressures within the automotive supply industry call for technologically and economically superior components, such as bearing shells, and a solution that is free from toxic lead, offers higher strength and utilises alternative process routes to the current state of the art. The aim of the project is to develop a holistic manufacturing route for bearing shells using powder processing via thermal spraying, as the requirements for bearing shells make a composite material essential. In this project, aluminium-based alloys are being developed and processed into powders via gas atomisation for application using HVOF. A new burner and nozzle geometry, along with optimised processing parameters, are being developed to enable the coating of such low-melting-point alloy systems. A comprehensive analysis of the coating process, the parameters and the resulting coatings enhances technological understanding and ensures quality. Finally, coated bearing shells will be tested under realistic operating conditions in internal combustion engines, thereby achieving TRL6. Within the scope of this project, Chemnitz University of Technology is responsible for coating development and the associated determination of optimal spraying parameters, and is therefore closely integrated with the sub-projects (powder production, burner prototype design, component post-processing and analysis) of the participating project partners.

The project investigates the potential applications of microwave plasma torches in thermal processing systems and compares them with conventional hydrogen and natural gas burners. To this end, a wide range of process parameters – such as feed gases, temperatures and mixtures – are systematically varied in order to investigate in detail the effect of microwave plasma torches on furnace lining materials. Based on these findings regarding plasma properties, the integrity of the burner components and process safety, recommendations can then be derived for the use of microwave plasma torches in existing and new thermal processing plants.

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.

The objectives of the Bladeprotect³ – OVBA sub-project are the selection and optimisation of materials, as well as the development of a process for metallising the leading edges of wind turbine rotor blades using thermal spraying. To this end, the proposed project will develop a manufacturing process chain in which the individual technologies work together to form coordinated sub-processes. A key focus at Chemnitz University of Technology is the development of metallic alloys that enable high bond strength to the rotor blade substrate and provide multifunctional protection within a coating system comprising a bonding layer and a functional top coat. A key aspect of this is the selection of filler materials and the investigation of modifications to the material composition with regard to functional properties. Furthermore, a solution for coating application via wire arc spraying using the previously developed metallic alloys is proposed, which represents a new approach in the field of wind energy. The technical functionalities of these metal coatings are comprehensively characterised in terms of their microstructure, adhesion strength and relevant property parameters. Building on this, the development and optimisation of coating parameters for wire arc spraying are investigated. Furthermore, the systematic investigation extends to the parameters for the surface preparation of the rotor blade substrates. As the coating adhesion mechanism is essentially characterised by mechanical interlocking, the topography and roughness of the substrate contribute significantly to the quality of adhesion. Using fractal design principles, a quantitative estimate of the bond strength – and thus the suitability for the intended application – can be developed. Finally, functional tests are carried out to validate the practical suitability of the coatings. These include electrochemical corrosion and tribological measurement methods carried out in a laboratory setting. The technical functionality of the multifunctional protective coating is characterised by high adhesion strength and a microstructure with few defects, whilst simultaneously exhibiting promising functional properties.

Meeting the growing demands in surface engineering – such as hardening surfaces in a targeted manner, for example through plasma nitriding, and determining the required process controls with precision – requires not only an in-depth understanding of the process but also extensive process development. To reduce the amount of experimental work required for this, numerical, model-based simulations are increasingly being used. However, state-of-the-art methods only allow plasma nitriding to be simulated under certain simplifications. Modern developments in mathematical modelling, information technology and mathematical algorithms enable the analysis of complex models with a high degree of precision. The project involves incorporating the effects of nitrogen and carbon contents – specifically their displacement mechanisms and solubility limits – on the phase transformations during plasma nitriding. In addition to mathematical modelling, the inverse calculation of the physical model parameters from plasma-nitrided layers is also a key part of the project. For the simulation, highly stable numerical methods developed in recent years are being put into practice.

The aim of the project is to determine and predict the influence of hydrogen addition in thermal processing plants on the mechanical properties and service lives of heat-resistant steels under combined thermochemical and cyclic mechanical loading, under conditions relevant to industrial applications. The results of these investigations are made available to plant manufacturers, service providers and materials suppliers. The data provide evidence of the corrosion behaviour and mechanical strengths of the materials used and their joint zones under the altered conditions of hydrogen combustion. This enables companies in the sector – particularly SMEs – to design future plants more precisely and to adapt existing plants in a targeted manner for use with hydrogen. The insights gained allow for the extension of costly maintenance intervals and the avoidance of unplanned plant outages. The aim is to ensure that the use of these materials in industrial systems fuelled by hydrogen is reliable, efficient and safe, thereby facilitating the transition to a low-carbon and sustainable energy supply.

CoCrMo is the standard alloy for dental implants and is currently produced almost exclusively by casting. 3D printing offers significant advantages in this regard in terms of customisation and design freedom. Against the backdrop of the growing market trend towards patient-specific treatments in dentistry, there is an increasing demand for efficient, bespoke implant solutions. However, a major technical challenge for successful market entry is the surface quality of additively manufactured parts, as the powder-bed fusion process leads to undesirable particle adhesion. The development of a holistic, closed-loop process chain offers a promising solution here to overcome this hurdle and make the technology viable for patient-specific implant restorations.
The aim of the project is to develop a comprehensive additive manufacturing process for CoCrMo dental implants. The focus is on optimising the alloy composition in terms of wear resistance, passivity and biocompatibility. In addition, robust and reproducible printing parameters must be developed for complex geometries. The surface finish is first specifically improved using electrolytic plasma polishing (EPP) to remove any roughness caused by the printing process. Finally, the surface is functionalised using a physical vapour deposition (PVD) coating to further optimise the biocompatibility of the implants and enable optimal tissue integration.
The partners include AddPark and plasotec GmbH (manufacturing and processing), as well as Chemnitz University of Technology and Atatürk University (alloy and powder development, surface treatment and biocompatibility studies).

Thermal spray coatings are used in numerous industrial applications, including to improve wear and corrosion resistance and to specifically tailor electrical and thermal properties (insulation or conductivity). Due to the highly dynamic nature of the spraying processes and the complex interactions between process parameters, particle properties and coating formation, quality control is of particular importance. However, currently available testing methods are often destructive, time-consuming or can only be used to a limited extent in-process. There is therefore a considerable need, particularly for small and medium-sized enterprises, for a fast, cost-effective testing solution that can be used on-site.
The aim of the IGF project ‘CoatAlyse’ is to develop a portable, non-destructive rapid test for the quality-related characterisation of thermally sprayed coatings directly in the production environment. By analysing electrochemical corrosion parameters using gel electrolytes and a customised measuring cell, the aim is to establish a robust correlation between the measurement signal and key coating properties. This will enable quality assessment close to the production process, reduce scrap and sustainably improve process stability. In the long term, ‘CoatAlyse’ aims to enable SMEs to monitor the quality of thermally sprayed coatings more efficiently and to strengthen their competitiveness in a targeted manner.

The overall objective of the Hy²Cycle collaborative project is to develop resource-efficient and recyclable cells and stacks for fuel cells (FC) and electrolysers (EL). New concepts for reversible and recyclable high-pressure alkali electrolyser/FC and PEM electrolyser/FC systems are being developed jointly. The development of recycling-friendly designs ranges from cell design through to energy-efficient manufacturing and, as a result of stack development, aims to take into account and implement novel recycling processes in line with a circular economy right from the design stage.

Hy²Cycle is a collaborative project run by the Saxon Hydrogen Union.

Green hydrogen plays a central role in the transition to a low-carbon and sustainable energy future. Efficient production is crucial to utilising hydrogen as a viable and scalable solution, ensuring economic viability, conserving resources and reducing the impacts of climate change. Alkaline water electrolysis (AEL) is particularly well-suited to the large-scale production of green hydrogen due to its robustness and sustainability. It is characterised by high system stability and a long service life. Furthermore, it offers a high tolerance to fluctuations in the power supply, which makes it particularly attractive for operation with renewable energy sources. The performance of the cathodes plays a central role in the overall efficiency of the electrolysis process. It depends largely on the available reaction surface area, the electrical conductivity and the catalytic activity of the material. Cost-effective solutions therefore rely on non-precious-metal-based electrode materials. Nickel-based systems offer a balanced approach in terms of cost-effectiveness and efficiency. One approach to enhancing the performance of such materials is to increase the reactive surface area. Fine-pored, open-pored structures are particularly suitable for this purpose, as they enable improved gas diffusion and optimised mass transfer. Thermally sprayed coating systems are particularly well-suited to this approach. By precisely adjusting the porosity and internal surface area, catalytic activity can be increased, gas bubble detachment improved and mass transfer optimised, which enhances both the electrolytic performance and the durability of the electrodes. Raney nickel represents a promising basis for thermally sprayed coatings due to its high catalytic activity and stability in alkaline media. In the planned project, new nickel-based alloys will be developed and processed by thermal spraying, with the internal porosity specifically increased through the selective leaching of components of the coating system. This results in a large-area, highly active and structurally stable cathode surface. The resulting porous cathode structure will be tested on an industrial scale to assess its potential for improving hydrogen production efficiency and reducing energy consumption in alkaline electrolysis.

Green hydrogen is regarded as a promising zero-emission energy carrier for meeting the targets of the Climate Action Plan 2050 and developing a circular energy system. The development of innovative cathode solutions is essential to achieving competitive production via alkaline water electrolysis. This project aims to develop nickel-aluminium-based Raney nickel cathodes, which are produced by thermal spraying and activated by leaching. This combination of processes significantly increases the specific surface area of the open-pored sprayed structure through the partial removal of aluminium-rich phases, thereby improving cathode performance. Novel wire-in-wire materials are used as filler wire additives, enabling alloy modification whilst maintaining homogeneous processing properties. Through detailed characterisation of microstructural and functional properties throughout the entire process chain, the aim is to initiate the cost-effective production of green hydrogen on an industrial scale.

The focus of sub-project B03 is on establishing an active, defined fibre orientation in short- and long-fibre-reinforced plastics (FRP) and a defined transition zone at the interface with continuously reinforced or non-reinforced substructures. Active alignment of the fibres is to be achieved by means of external magnetic excitation in an isostatic state. The research focuses on developing a suitable coating process for the production of magnetically coated carbon fibres (mc-CF), as well as the production of polymer composites incorporating mc-CF, and the associated experimental and numerical investigation.
This sub-project forms part of the DFG Collaborative Research Centre “SFB/TRR 402”. The project is dedicated to the development of novel production technologies for lightweight structures that are resource-efficient, sustainable and, at the same time, high-performance. The aim of these technologies is to significantly reduce energy consumption and carbon dioxide emissions both during production and during the operation of vehicles and machinery. The focus is on optimising the transitions between different materials in fibre-reinforced plastic composites. These transitions currently present one of the greatest challenges for mass production, as they significantly influence the load-bearing capacity and service life of the components. With the help of what is known as 3D grading, the aim is to produce smooth material transitions that are specifically tailored to the load requirements of the components. This method allows for a gradual change in the reinforcement structures, which improves the mechanical properties and optimises material usage.

The AlSiCoat research project is developing a sustainable coating concept for blades used in agricultural machinery. The aim is to replace conventional tungsten carbide–cobalt-based wear-resistant coatings with more environmentally friendly alternatives. These established systems contain critical raw materials such as tungsten and cobalt and are coming under increasing regulatory and environmental pressure.
The project therefore aims to develop novel aluminium metal matrix composites (AMCs) with embedded silicon carbide (SiC) particles. For the first time, these powders are to be produced from semi-finished AMC castings and applied to machine tools’ cutting edges using laser cladding. The combination of innovative powder production, an optimised coating process and application-oriented testing is intended to result in wear-resistant, tribocorrosion-resistant coatings.
The sub-project led by Chemnitz University of Technology (IWW) focuses on the development of a test method and a test rig for assessing combined wear and corrosion resistance. To this end, a tribocorrosive, unidirectional abrasion wear test is being developed which replicates the real-world operating conditions of agricultural tools as closely as possible. The results enable a quantitative assessment of the new coatings and support the optimisation of the entire process and materials system.

Many components must withstand periodically occurring load cycles throughout their service life. Long service lives with high allowable loads are of great technical and economic interest in this context. For components subjected to this type of cyclic loading, it is necessary to select suitable materials and optimise the geometric design to achieve high realisable fatigue strengths. Specified minimum fatigue life cycles, tailored to the specific application, must be withstood without the formation of cracks. As the component surface is the preferred location for crack initiation under high-cycle fatigue (HCF) loading, the geometric and material properties have a decisive influence on the cyclic load-bearing capacity and thus on the fatigue strength. This means that, in addition to strength, hardness and macroscopic surface topography, the notch effects resulting from microstructural features at the microscale also exert an influence. However, the mechanisms by which these microstructural factors influence fatigue strength have so far been inadequately investigated. The aim of the project is to characterise the influence of the near-surface microstructure on fatigue strength not only qualitatively but also quantitatively, in comparison with the macroscopic, manufacturing-induced surface topography, in order to take all relevant factors into account when designing a component to achieve improved operational properties.

The industrial manufacture of components involves the sequential linking of manufacturing processes to produce products with a defined set of properties. The challenges lie in optimising the manufacturing process, addressing uncertainties inherent in the process, and achieving global optimisation across the entire process chain. Multi-criteria optimisation is challenging, as there are conflicting target parameters relating to processing and functional properties.

Process chain optimisation is to be carried out in ProModFun using an experimental approach and data-driven modelling. First, the process chain comprising (1) thermal coating, (2) turning and (3) diamond smoothing will be established to produce a functional surface with a graded increase in hardness close to the surface. The innovative property profile is to be demonstrated using the ‘guide roller’ component as an example. Through thermal coating (primary shaping), surfaces made of manganese hard steel are applied to rotationally symmetrical components and then adjusted in terms of core and edge properties by turning and diamond finishing. The target parameters of the process chain to be optimised are to be influenced as follows: (1) maximise surface hardness, (2) minimise surface roughness, (3) maximise the oxide content of the coating system, and (4) maximise the energy efficiency of surface production.

Sensor technology is integrated into the manufacturing processes and the measurement data is used for modelling. The methodological approaches employed are statistical modelling and multidimensional, pattern-based description using grey-box AI algorithms (fuzzy pattern classification). These enable the quantification of various types of uncertainty and the forward coupling of the process chain. This is followed by the development of a method for inverse multi-criteria optimisation across the entire process chain for the purpose of global optimisation.

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.

The ‘FerriKo-EL’ project is investigating the use of cost-effective and resource-efficient ferritic stainless steels for water electrolysis. Compared with the commonly used austenitic steels with a high nickel content, ferritic steels are based on chromium as the main alloying element, which is significantly cheaper and more sustainable. At the same time, the absence of nickel results in reduced formability and corrosion resistance, which has so far limited their use to flat – and therefore less efficient – flow field structures. Furthermore, without suitable surface treatment, the aggressive media and high electrical voltages in electrolysers lead to accelerated degradation of the steels.
Studies have shown that the chromium content in ferritic steels allows the formation of self-passivating layers with very high corrosion resistance whilst maintaining sufficient electrical conductivity. The aim of FerriKo-EL is to systematically investigate this approach and apply it to ferritic electrolyser plates. To this end, the surfaces of the plates are specifically treated or coated using various methods in order to optimise the formation of protective coating systems. In parallel, tailored forming strategies are being developed to significantly improve the formability of the materials and enable the production of flow fields with deeper channel structures. This allows the performance and efficiency of the novel electrolyser plates to be significantly increased. Through the combination of materials development and advanced process design, FerriKo-EL makes a significant contribution to reducing costs, increasing efficiency and enabling the sustainable production of hydrogen as part of the energy transition.

The aim is to develop a recycling technology for aluminium that produces material of a quality suitable for wire drawing processes, ultrasonic metal welding (USMW) and use in electrical components. USMW is an innovative joining process that is particularly relevant for applications in electromobility, as it enables high-strength, material-bonded and electrically conductive joints without the need for filler materials. A key application lies in wiring harness connections for electric and hydrogen-powered vehicles. Aluminium enables a weight reduction of up to 40 per cent in cable harnesses, thereby contributing to a reduction in energy consumption and, indirectly, in CO₂ emissions. Furthermore, aluminium offers greater availability and lower material costs compared with copper.
At present, primary aluminium is predominantly used for electrical applications, as there is a lack of suitable recycling technologies for secondary aluminium wires with the required electrical properties. However, the development of such a technology is crucial to the sustainability of the energy transition. The use of recycled aluminium reduces greenhouse gas emissions, lowers the energy required to source the material and minimises the demand for primary raw materials such as bauxite. At the same time, it conserves natural resources and reduces the environmental impact of raw material extraction.
Furthermore, the expansion of relevant recycling technologies offers economic potential through lower production costs and the strengthening of regional value chains. The project is therefore in line with the Free State of Saxony’s innovation strategy and the Raw Materials Initiative of the Saxon State Ministry for Economic Affairs, Labour and Transport, in particular with the aim of establishing Saxony as a centre for secondary raw materials.

The project aims to reduce scale formation on metals, such as steel and copper, within the hot rolling process chain, with a view to conserving resources and reducing CO₂ emissions. This is achieved by combining experimental investigations with simulation-based predictions of scale formation within hot forming process chains. These approaches are intended to reduce scale formation whilst maintaining component quality and to make scale removal measures more efficient. As over 90 per cent of copper and steel products manufactured worldwide are hot-formed, the project offers considerable potential for savings in terms of more efficient use of resources and energy, provided the set objectives are successfully achieved. The development of an AI-supported forecasting tool to map the heating and descaling stages is the primary means of achieving these objectives. The training data underlying the forecasting tool is generated through laboratory tests and the modelling of hot forming process chains. To model scale formation, specially developed subroutines are created within established hot forming simulation programmes. These models are then validated in an industrial setting. This enables the prediction tool to be provided with extensive training datasets to identify correlations between the process variables and scale growth, as well as scale properties. This enables the industrial partners to identify energy-saving potential during heating, descaling and hot forming in a time- and cost-efficient manner. Consequently, the successful implementation of the prediction tool into existing furnace control and descaling programmes enables the project partners to design their hot forming process chains in a way that conserves resources and reduces energy consumption.

Moulded rubber parts are of significant economic importance and are used in many industries, for example as seals in mechanical engineering or as elastic components in the automotive sector. They are usually produced by moulding using tools, followed by vulcanisation. However, this tried-and-tested process is primarily cost-effective for large production runs and restricts design freedom; small-batch production and design changes are costly and time-consuming.
Additive manufacturing of vulcanisable rubber compounds is still at an early stage of research. Initial attempts using screw extruder prototypes have so far been limited to simple geometries. Challenges include developing a formulation that is both printable and vulcanisable, ensuring dimensional stability during curing, and precisely controlling adhesion, particularly in multi-material applications.
Suitable materials and printing systems enable the rapid, tool-free production of prototypes, spare parts, complex geometries and multi-material components, such as rubber-metal combinations. The project therefore examines the entire process – from the formulation of the rubber compound, the development of a print head and research into 3D printing parameters, right through to the study of adhesion between rubber and metal surfaces.

The project aims to develop a green and smart electroplated coating using modular, robot-based electroplating with in-line process monitoring. This enables the reliable and reproducible coating of relevant aircraft components, even in small and medium batch sizes.
The sub-project run by the Chair of Materials and Surface Engineering focuses on the development of a robot-assisted electroplating system that covers the entire process chain for component coating. To this end, an existing plant is being expanded and modernised to incorporate larger process vessels for coating individual parts and to accommodate the use of rack-mounted components. The level of automation is being further increased in order to meet the quality requirements for aerospace components. This includes automatic bath maintenance and coating analysis. These upgrades are crucial for validating new simulation models and for gaining a better understanding of the relationships between process, microstructure and properties. The research aims to reduce resource consumption and the scrap rate, minimise the volume of waste water and contribute to a more environmentally friendly production of aircraft components.

Particle-reinforced aluminium matrix composites (AMC) offer great potential for a wide range of applications, which is currently limited by material and manufacturing constraints. Large-scale applications require robust, reproducible and continuous manufacturing processes, which are made possible by new continuous AMC casting processes. At the same time, material quality is compromised by process-induced inhomogeneities. Conventional melt-metallurgical AMC manufacturing processes use aluminium casting alloys as the matrix material. Consequently, AMC materials have so far been available mainly as simple semi-finished products or ingots. Strip-shaped semi-finished products for forming processes or sheet metal applications do not yet exist, but would significantly expand the range of applications. The two-roll casting process combines melt-metallurgical primary forming with thermomechanical forming, and enables the production of strip-shaped semi-finished products with a reduced proportion of material inhomogeneities.
The aim of the research project is to establish correlations between process, microstructure and properties, so that different AMC material states can be taken into account in numerical process design. To this end, targeted characterisation methods are being employed to analyse material-process interactions and, building on this, to further develop material modelling and simulation. To this end, the AMC matrix materials previously used in the project—cast aluminium alloys (AlSi7Mg, AlSi9Mg)—are being replaced by heat-treatable wrought alloys. In addition to material development and process design, a comprehensive characterisation of the process steps – stir casting, casting rolling, hot rolling and deep drawing – is being carried out, including the necessary heat treatments. This enables numerical predictions to be made regarding forming forces, material flow, microstructure development and damage mechanisms.

Protecting components against wear is a key prerequisite for the performance and service life of technical systems across many industrial sectors. In particular, hardmetal coatings based on tungsten carbide and cobalt (WC-Co) currently represent the state of the art, as they offer very high wear resistance. At the same time, these systems are coming under increasing pressure: cobalt is considered a critical material due to health risks and is subject to regulatory restrictions, whilst tungsten is classified as a critical raw material with potential supply risks. Furthermore, WC-based coatings have limitations in terms of corrosion resistance and high-temperature resistance. There is therefore a growing need for high-performance alternatives.
The research project aims to develop a new generation of wear-resistant coatings based on high-entropy carbides (HEC). These materials consist of several transition metal carbides in approximately equal proportions and form stable mixed-crystal structures with high hardness and thermal stability. Through the targeted selection of elements, the use of critical or health-hazardous raw materials can be reduced and supply chains diversified.
The project involves synthesising suitable HEC compositions, combining them with alternative binder metals – in particular iron-based alloys – and, for the first time, processing them into agglomerated and sintered coating powders with a hard-phase content of 80 vol.%. Wear-resistant coatings are then produced using high-speed flame spraying and laser beam cladding, and are investigated in terms of microstructure, wear resistance, corrosion resistance and high-temperature resistance, and compared with current state-of-the-art coating systems. The aim is to develop a high-performance, cobalt-free alternative to existing cemented carbide coatings.

Research is being conducted into a thermomechanical treatment (TMB) for sheets made of martensitic stainless steels (MNS) with minimal austenitisation times. The aim is to develop a short-duration TMB for efficient sheet hardening, which enables high degrees of forming with short process times and ensures the desired material properties. This offers potential for reducing energy consumption and improving material yield.
Rapid heating followed by quenching creates thermodynamic states of disequilibrium which influence the solubility of accompanying and alloying elements, as well as the phase transformation temperatures. Established TMB models for MNS are therefore not directly applicable to short-term processes. In this project, X46Cr13 steel is heated into the austenite region using inductive rapid heating at heating rates of at least 100 K/s, formed without a holding time, and subsequently quenched. In this process, forming steps in the stable and metastable austenite regions are investigated. Short-term TMB is carried out using a forming simulator and a forming dilatometer to analyse phase transformation and forming behaviour. The influence of heating rate and austenitisation temperature on the solution state of the alloying elements is investigated on the basis of the precipitation state and the residual austenite content using SEM, EDX, XRD and thermophysical calculations. Supplementary mechanical and chemical characterisations are used to identify a process window that both enhances the formability of the MNS sheets and ensures defined application properties at room temperature.
In the final phase of the project, a demonstration tool and a demonstration process for the production of thermomechanically treated deep-drawn parts using rapid inductive heating will be developed and tested in order to demonstrate the technological added value compared with the current state of the art.

The incremental sheet metal forming (IBU) process offers the possibility of manufacturing components in small batch sizes in a cost-effective manner that meets specific requirements. The in-service behaviour of manufactured components is largely determined by the prevailing residual stress state. The aim of the research project is to improve the in-service behaviour of incrementally formed high-strength components by specifically controlling the residual stress state during the industrial manufacturing process. The residual stresses are introduced locally into the workpiece through the process control of incremental sheet metal forming, in order to improve the component properties. In the transfer project with Faurecia Autositze GmbH, the findings are being applied to meet industrial requirements. To this end, the range of materials analysed to date is being extended to include high-strength dual-phase steels for industrial use, and application-specific geometries are being selected. In addition to component performance under static and cyclic loading, the focus is on the geometric accuracy of the manufactured components. To introduce additional compressive residual stresses close to the surface and reduce the process force, a concept involving oscillating die movement is being tested. The simultaneous use of several forming dies is intended to enable a reduction in process time.

The sub-project being carried out by Chemnitz University of Technology as part of the TiHydrAero consortium addresses the funding policy objective of ‘environmentally friendly aviation’. To achieve this core objective and significantly reduce CO₂ and NOx emissions, new propulsion technologies and energy storage systems must be developed. In this context, hydrogen and lightweight construction are taking centre stage. Additive manufacturing processes, such as laser powder bed fusion (LPBF) and laser metal deposition (LMD) – each in combination with high-performance materials – are the key technologies for achieving this objective.
LPBF opens up unique opportunities for designers to optimally tailor the design of system components to the prevailing loads. This design freedom allows for the achievement of the highest functional packing densities, thereby significantly increasing the degree of lightweight construction. Particularly with regard to high-performance materials, this process has already been well-proven for the titanium alloy Ti-6Al-4V and is also qualified for aerospace applications. However, in the α+β phase, this alloy is highly susceptible to hydrogen embrittlement. It is anticipated that this property can be significantly improved through geometry-dependent process control in the LPBF process. A complementary approach is also being pursued through the development of processing parameters for the LMD process. The locally confined additive material deposition allows for the structural implementation of a layered composite design. The functional separation of the surface and the base material also offers solutions tailored to load distribution. Furthermore, the high design freedom afforded by the locally confined material deposition enables specific repair requirements to be met.
Research is being carried out into the titanium alloy newly developed by the project partner IWT for both the LPBF and LMD processes. Here too, the aim is not only to achieve the highest possible material densities but also to significantly reduce hydrogen absorption by means of optimised grain structures. Should these measures alone not yet lead to the desired result, investigations into shot peening and the diffusion-controlled introduction of impurity atoms into the surface layer will be carried out.

Thermal spraying of multi-component coating materials offers great potential for the targeted adjustment and enhancement of coating properties. In particular, multi-component oxide systems allow properties such as wear resistance, hardness or electrical properties to be tailored by combining different material components. At the same time, however, complex material- and process-related interactions arise, the influence of which on microstructure and properties has so far been insufficiently understood. This applies in particular to changes in the powder materials during the spraying process, which are determined by process-dependent melting behaviour and possible in-situ reactions between the components.
Against this background, the project aims to systematically investigate the fundamental relationships between powder material, process control, the resulting microstructure and coating properties. The ternary oxide system Al₂O₃–Cr₂O₃–TiO₂ serves as the model system. A key focus is on analysing the process-induced changes in the powder particles and their influence on phase formation and microstructural development within the coating. To this end, experimental powder materials are produced with deliberately varied homogeneity in elemental distribution.
Through a combined investigation of the spraying process and a detailed characterisation of the resulting coatings in terms of microstructure and functional properties, fundamental relationships between powder material, process, microstructure and properties are derived. The results contribute to a better understanding of the mechanisms involved in the processing of multi-component oxide materials in the thermal spraying process and provide a scientific basis for the targeted development of high-performance multi-component coating systems.

Innovative materials and manufacturing concepts make it possible to meet the often conflicting requirements regarding processing and functional properties. Austenitic high-manganese steels (HMnS) offer significant, as yet untapped potential for applications in the field of surface engineering. They are characterised in particular by high work hardening under impact and shock loads, thereby enabling applications involving combined tribological stresses. The production of the powdered starting materials via gas atomisation and their processing using modern coating technologies such as HVOF and HS-LMD ensure a high material quality of the coating system. Mechanical post-processing allows the property profile to be adjusted in line with the tribological stress profile. A combination of thermal coating technologies and the refinement of HMnS coating systems thus enables surface functionalisation with graded coating properties achieved through work hardening. IronWorkCoat aims to provide sustainable coating solutions for applications subject to complex tribological stresses.

Cut surfaces produced by high-speed shear cutting (HGSS) may contain adiabatic shear bands (ASB), depending on the material and the selected process parameters. These are homogeneous zones that are clearly distinguished from the base material in terms of microstructure and exhibit a property profile that differs significantly from that of the surrounding material. However, the structure-property relationships of HGSS cut surfaces have so far remained largely unexplored. Sub-project 1 therefore focuses on providing a scientifically sound answer to the question of how HGSS cut surfaces behave under tribological, corrosive and cyclic mechanical loading. This is directly linked to the need to gain a fundamental understanding of the mechanisms at work and, consequently, to identify the relationships between process, microstructure and properties. A prerequisite for this is the interpretation – to be carried out in consultation with the research group partners – of the results of the wear, corrosion and fatigue tests, as well as the residual stress analysis; that is, the correlation of the determined cross-sectional properties with the process parameters and the resulting microstructure. The research results achieved in WP1 form the basis for evaluating the service properties and thus the practical suitability of HGSS cross-sections. Through feedback with the other sub-projects, the results also enable direct influence on the design of the HGSS process and thus the targeted adjustment of the properties of the functional surface.

High-speed shear cutting (HGSS) represents an economically and environmentally attractive alternative to conventional cutting processes such as standard, precision or laser cutting. HGSS offers great potential, particularly for high-strength and ultra-high-strength steels, but also for light metals, in terms of producing cut surfaces that can be used directly as functional surfaces without the need for further mechanical, thermal or thermochemical post-processing steps. This is due to the fact that, depending on the material and the process parameters, adiabatic shear bands (ASB) can form during HGSS, within which the material separation then takes place. The resulting cut surfaces are characterised by high hardness, minimal edge retraction and low surface roughness, and exhibit virtually no burr. However, there is currently a lack of fundamental understanding of the mechanisms leading to the formation of ASBs in HGSS. This, in turn, is essential if the exceptional cut surface properties described are to be utilised in a targeted manner. The FUNDAM³ENT research group is therefore dedicated, as part of an interdisciplinary consortium, to investigating the material- and process-related factors influencing the formation of ASBs during HGSS. The overarching aim of the research group is to develop a model grounded in materials science and process technology that describes shear band formation in HGSS as comprehensively as possible, i.e. for various materials and across a wide range of process parameters. This is to be achieved by pooling expertise from the fields of materials science, materials engineering and production engineering. Key research questions being investigated in greater depth by the research group include, for example, the influence of various microstructural components and the deformation history on the tendency for shear bands to form, or the question of whether shear bands can also be produced in highly thermally conductive materials, such as aluminium. Furthermore, research is being conducted into the extent to which the strain rate during the HGSS process determines the microstructure, geometry and properties of the shear bands, and whether a material’s melting or recrystallisation temperature influences ASB formation and the resulting microstructure. Extensive experiments across various strain rate ranges of the HGSS process (10²–10⁵ s⁻¹) not only generate comprehensive process knowledge but also form the basis for a sound understanding of the microstructural effects occurring within the shear band. This is supported by multi-scale simulation methods at both the microstructural and process levels. Systematic investigations into the material behaviour of HGSS cut surfaces under tribological, corrosive and cyclic mechanical loading enable an analysis of the relationships between the shear cutting process, the microstructure and the resulting cut surface properties.