The Light Metals & Mechanical Testing group at the institute for general materials properties focuses on the one hand on the research of aluminium, magnesium and titanium alloys, especially for structural automotive and aerospace applications. In this context, activities are focused on determining the correlation between process parameters, the emerging microstructure and the resulting properties. In combination with research into dominant damage mechanisms, material/component properties can thus be specifically influenced and improved. Current research topics include wrought and cast aluminium alloys as well as titanium alloys. Other materials, such as copper alloys or electrical steel sheets, are also the subject of current work. In all cases, an in-depth understanding of the process-microstructure-property correlation, based on extensive material characterization, is essential.
Main aspects of the research include:
Exploiting the potential of materials through a deeper understanding of process-microstructure-property correlation.
Increasing the application limits and sustainability of materials through a deeper understanding of the process-microstructure-property correlation and the analysis of damage mechanisms.
Optimization of materials with regard to special applications or requirements
Extension of the basic understanding of deformation and damage mechanisms of metallic materials
In the field of mechanical testing, the focus is on both methodological issues and the determination of the mechanical properties and deformation behaviour of (mostly metallic) materials under a wide variety of load cases. In addition to deformation behaviour under quasi-static tensile and compressive loading, cyclic and/or time-dependent deformation behaviour is also investigated using fatigue and creep tests. For the characterization of the mechanical properties, a wide range of testing equipment is available at the institute. Specific load cases, such as fretting fatigue, are also considered.
In addition to publicly funded basic and applied research projects, partner projects are also carried out in cooperation with industry.
TiAl6V4 (Ti-64) is one of the most commonly used alloys in aerospace industry. Nowadays, structural parts are milled from solid blocks. This results in a degree of machining of up to 96 %. Thus, aerospace industry is in need of an advanced technology, which improves the ecological footprint and the costs for structural parts. This becomes even more important as the market demand is increasing steadily.
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Extrusion profiles made from Al-Mg-Si alloys are used in car manufacturing as rods, beams and members as components for the car frame and body. For such safety components, the applied alloys need a high strength and a high degree of ductility at ambient temperature in order to not fail in a brittle but ductile manner and protect the passenger in the interior.
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The Institute I of FAU Erlangen-Nuremberg is working on the joint project TISTRAQ in cooperation with the project partners HEGGEMANN AG (HEG) and DYNAmore GmbH (DYN). The main objective of TISTRAQ is the development of a new quench forming process (TISTRAQ process) for the energy- and material-efficient production of Ti-6Al-4V sheet metal parts for aerospace applications. The sheet metal parts produced are expected to have improved mechanical properties compared to their initial state.
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The aim of the project HyLight is the development of new lightweight constructions of rotating components by rotational friction welding. The produced aluminium-steel- as well as aluminium-cast iron-connections show the relevant interactions between process parameters and therefore the effect on microstructure and mechanical properties.
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The drive for reduced CO2 emissions is currently more pronounced than ever before, which is why the development of aluminum alloys, which are capable of increasing lightweight potential in automotive engineering, is a research priority. Since a large proportion of the accruing CO2 is attributable not to the operating time of the vehicles but to the extraction of raw materials for their production, a concept for the sustainable fabrication of structural components will be developed as part of the “Green-Al-Light” project.
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Due to the properties of aluminium and the associated lightweight potential, it is increasingly used in the automotive sector. Extrusion profiles made of Al-Mg-Si alloys are often used for safety relevant components that protect the passenger compartment in the event of a crash. Ensuring high strength with sufficient ductility in the application at the same time is a major challenge.
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