Plastics Research Development Contract Project

PLASTICS Research Development Research Contract Project

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  • Development of a calculation and dimensioning model for the definition of suitable surface structures for tribological applications of plastic components
  • Higher resource efficiency through expanded thin-wall injection molding technology using thermal barrier layers (TBC) in the tool
    Short title: Thin-wall injection molding

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Metals Metal NF Research Development Innovation Projects Contract

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current projects listed:
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Manufacturing process for powder metallurgical aluminum foams with optimized
Microstructure through mechanical alloying

Aluminum foam produced by powder metallurgy is an excellent lightweight construction material with a high
Vibration damping capacity. It is used in a variety of niches, including in
Machine tool assemblies also used in series. The establishment in areas with high
Safety requirements, such as in aircraft construction, on the other hand, were not previously possible. The cause is there
especially in an inhomogeneous foam structure. So far, this can only be influenced to a limited extent and therefore hardly
predictable. This is regrettable, since the enormous potential for lightweight construction is too considerable there
technical and economic improvements would result. In the intended project, the
Production of a preform powder through the process step high-energy ball milling. Using this procedure
it is possible to generate a homogeneous distribution of brittle particles in a ductile matrix. It will therefore
usually also for the powder metallurgical production of particle-reinforced
Aluminum matrix composites are used. The first goal is to develop an industry-standard
Process chain. Furthermore, it must be worked out within which limits and under which boundary conditions
Foams can be produced whose properties are subject to only slight fluctuations. In addition
becomes a significant improvement in properties compared to conventional powder metallurgical foams
aimed at. If the project is successful, SMEs that are involved in the production route of the
can bring in the desired semi-finished products. For foam manufacturers, this includes direct improvement
of products and the associated forward-looking portfolio expansion, the clearest increase in
Competitiveness expected. Processors also benefit from semi-finished foam products as well
End users of the products because of the better predictability and the new product properties
should be able to be developed

 

Linear joining of profile composite systems with increased Tightness requirements

The aim of the project is to develop and implement a new type of extruded profile concept for
Manufacture of profile composite systems with increased tightness requirements. Especially in the context of
The tightness of assemblies is of fundamental importance to electromobility. Current battery case
with floor groups made of extruded profiles meet the challenge of tightness in the joints
by means of friction stir welding, which, however, entails a time-consuming and costly production.
The solution path to achieve the goals includes, through a targeted, simulation-based
Profile geometry development, the setting of the extrusion parameters and local cooling strategies,
To generate profiles with ideal properties for a downstream, optimized joining process. The
The joining process should be implemented in terms of forming technology, ideally on the basis of a press stroke, so that
the results can be used directly by SMEs from the addressed areas.
After the development of appropriate profile composite systems, the resulting tightness becomes linear
Examines connections and evaluates the results in the context of the manufacturing and joining process. The
Generated knowledge about the interrelationships between the locally available material properties, the
Joining operation and the resulting load-bearing capacity and tightness enable a comprehensive
Process understanding.
On this basis, the potential of electromobility, which among other things is due to the complex
and cost-intensive battery housing production can currently only be used to a limited extent. The
In this way, SMEs receive technological and economic benefits and can increase their
Achieve competitiveness.

 

Friction-based crack initiation in metal-forming joints of Wrought aluminum alloys

High-strength aluminum materials are used in automotive, rail vehicle and aircraft construction to
to replace existing steel structures with a more efficient lightweight construction. The
Utilizing the strength potential of the materials generates high demands on the
Structural fatigue strength. Recent studies show that the failure of
Connections joined by forming technology are caused by a friction-based crack initiation between the
Joining parts or between the joining part and the joining element is caused. Previous simulation approaches,
which are used to predict damage to base materials, among other things, can be derived from this
Reason cannot be transferred directly. There is a need to identify the relationships
between clamping force-based wear and crack initiation in such materials to
and to offer the opportunity to assess the fatigue strengths of the joints with little testing. The
Lack of knowledge about these fundamental facts is motivation for the one to be applied for
Research project.
With efficient strategies for mapping the mechanisms at work in the case of friction-based failure in the
numerical simulation, SMEs (e.g. manufacturers of joining tools, software simulation companies,
Suppliers of structural parts) will in the future be able to develop forming joints with regard to new
Execute design criteria fatigue-friendly. Through the holistic consideration of the joint
With regard to sampling and load-bearing behavior, the project results therefore lead to a significant
Increase in the competitiveness of SMEs through a significant increase in the efficiency of the assembly process.
In addition, with the help of the application-oriented simulation methods, the problematic high for SMEs can be achieved
Expenditure on the experimental characterization of the fatigue strength of the formed joint
Connections are significantly reduced

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Tools and Materials Research Development Innovation Projects Contract

Tools and Materials Research Development Innovation Projects Contract
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Hybrid spindle: Process-dependent setting of the spindle dynamics to increase productivity in machining

Various storage concepts for the hybrid spindle were initially developed and implemented in
Examined within the framework of numerical simulations with regard to the thermo-elastic behavior. The storage temperatures and thermal
Induced bearing deformations are used to design the preload element. The prestressing force is applied by the prestressing element via spring forces. A deformation of the spindle bearings leads to a change in the deflection and thus to a change in the preload force. The
adaptive prestressing element is therefore designed so that the change in prestressing force as a result
thermally induced deformations can be compensated. In cooperation with representatives from the industry, a practical maximum nominal speed of
n = 20,000 rpm and a rated motor power Pn = 60 kW. Based on the performance and
Speed ​​requirements, the dimensioning and the technical implementation of the electromagnetic active part of the motor. The biasing element and the switchable Winding systems were integrated into a V100 – S20 milling spindle from NN GmbH.
The resulting hybrid spindle was then put into a machine tool of the type NN PFV-1 integrated and experimentally investigated at the IFW. The experimental investigations include the implementation of modal analyzes and machining tests.
The steps involved in designing and testing the hybrid spindle are described in more detail below
… more in German

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Lime Mortar Research Development Innovation Projects Contracts

Lime Mortar Research Development Innovation Projects Contract

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Current projects: (please feel free to add offers / update in comments below – and get promoted!)

Lime-based solid reactor for CO2 separation from exhaust gases with regenerative recovery of the enthalpy of reaction (2020-2022):

The lime and cement industries are responsible for around 5% of global CO2 emissions. About half of the CO2 comes from the product itself through the limestone decomposition CaCO3 -> CaO + CO2. This CO2 cannot be avoided through the use of renewable energies. Therefore the CO2 has to be captured. In the project, a solid reactor is being developed that works according to the calcium looping process. Here the exhaust gas is compressed for CO2 exothermic absorption (CaO + CO2 -> CaCO3) and the gas is expanded for endothermic calcination (CaCO3 -> CaO + CO2) with the release of CO2. As a result, the exothermic absorption (carbonization) takes place at a higher temperature level than the endothermic calcination. The heat released is stored regeneratively in the particles of the reactor and then used for calcination. In preliminary tests, 250 cycles were carried out according to this method without the material burning to death (continuously decreasing CO2 absorption). Compared to previous calcium looping processes, not only is dead burning avoided, but the enthalpy of reaction is also reused, so that oxyfuel firing for calcination and the inefficient generation of electricity for carbonization are no longer necessary. The FSt. 1 Reaction kinetic experiments carried out on an existing thermoreactor, the FSt. 2 develops a process model and the FSt. 3 shows the mode of operation with an existing semi-industrial shaft reactor.

L’AmmoRE – Ammonia Recovery with Lime / Ammonia recovery from fermentation products from biogas plants in the form of ammonia water using lime (2020-2022):

The biogas plants make a valuable contribution to the renewable energy mix in Germany. At the same time, however, they also face the problem of disposing of the nutrient-rich digestate. Due to tightening of the European and national legal situation, agricultural application without prior removal is only possible to a limited extent, which leads to increased costs for the plant operator. The problem is particularly pronounced in regions with high levels of livestock processing due to the already existing nutrient surplus. Above all, the high nitrogen content in the digestate has a limiting effect. This is where the presented project comes in. By means of a stripping system converted for the use of milk of lime, digestate of various compositions is denitrified, and thus a limed digestate is obtained, which can be used again as liquid farm manure. The ammonia obtained is processed directly into marketable ammonia water, which is used, for example, in analytical chemistry or in flue gas cleaning. As a result, SMEs (especially lime and cement manufacturers, biogas plant operators) benefit across all sectors from an increase in competitiveness, the development of new sales markets, the conversion / construction of stripping plants, the spreading of denitrified digestate and the expanded range of uses of lime milk. The concluding technology and economic feasibility study will address both a scale-up and the use of ammonia water in various industries.
By fully utilizing the digestate, the project makes a valuable contribution to the circular economy. At the same time, the production of ammonia is more energy-efficient and climate-neutral than conventional production using the Haber-Bosch process. The decentralized extraction of ammonia also helps to reduce the greenhouse gases caused by transport.

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We DO work on co2 reduction, older and current Projects:

Direct CO2 avoidance
LEILAC (Low Emissions Intensity Lime And Cement) has the potential of a technological breakthrough that can enable the European cement and lime industry to significantly reduce its emissions while maintaining or even increasing its international competitiveness. With the best technologies currently available in the cement and lime industries, there is no way to economically capture carbon. Therefore, the most practical approach to reducing these emissions for the cement and lime industries has been to increase the efficiency of the ovens and use alternative fuels. The direct CO2 separation offers a common platform for CCU and CCS in both the lime and cement industries and can make these industries future-proof.

The LEILAC technology should enable a direct separation of the carbon dioxide in order to efficiently separate the unavoidable process emissions that arise during the lime and cement production. This is made possible by the special shape of the furnace, in which the resulting process emissions from the limestone are separated from the remaining exhaust gas. This means that the technology has the potential to use renewable fuels to achieve the target reduction in emissions by 2050. There are already concrete plans to operate the LEILAC furnace purely electrically. This enables both direct avoidance of CO2 and efficient CO2 separation of the amount of CO2 that occurs.

CO2 capture
Responsible use of natural resources and climate protection are central elements of a climate-neutral lime industry in 2050. As an indispensable basic industry, the lime industry is responsible for around 1.5% of the CO2 emissions of the German energy and industrial sector (UBA inventory report, 2017). About ⅔ of the CO2 is due to the raw material and cannot be avoided by using renewable energies in the combustion process. A CO2 separation with subsequent recycling (CCU) according to the idea of ​​the circular economy or – if unavoidable – CO2 storage (CCS) is the declared goal for fulfilling the German climate protection plans.

To achieve this goal, a fixed bed reactor is being developed as part of an AiF-IGF project, with which CO2 can be separated from exhaust gases in a much more energy-efficient manner than with known processes. The new approach is that the exothermic carbonization (CO2 absorption: CaO + CO2 → CaCO3) is carried out at overpressure and the endothermic calcination (CaCO3 → CaO + CO2) at negative pressure. As a result, the carbonization takes place at a higher temperature level than the calcination. The enthalpy of reaction released during carbonization is stored regeneratively in the solid reactor and used for calcination. In preliminary tests, up to 250 cycles were carried out without a decrease in CO2 absorption. Compared to previous calcium looping processes, this dead burning is avoided and the enthalpy of reaction is reused, so that oxyfuel firing for calcination and the inefficient generation of electricity during carbonization are no longer necessary. Calculations show that only approx. 10 to 20% of the energy of oxyfuel combustion is required. In further project steps, after successful CO2 concentration and separation, the focus is on the identification of the most suitable CCU application, e.g. B. CO2 mineralization or methanation.

 

Carbonation and mineralization
As part of the AiF research project “ECO 2: Development of the limestone powder CO2 washing process – practical optimization and ecological assessment” (AiF-IGF No. 18560N), the CO2 separation at a coal-fired power station in Wilhelmshaven was investigated with the help of a semi-technical demonstration system. The CO2 scrubber simulated the naturally occurring carbonate weathering in a process-technically accelerated manner. The CO2 exhaust gas is passed through a limestone powder-water suspension inside the scrubber, whereby the CO2 is converted into water-soluble hydrogen carbonate. The mineralized water produced can then be used directly for water restoration and buffering. As part of the project, long-term simulations were also carried out to evaluate the permanent storage of carbon dioxide in water and the chemical-ecological effects on flora and fauna. The ECO-2 process thus contributes on the one hand to climate protection by avoiding CO2 emissions and on the other hand to environmental protection and sustainability through the component of water remediation through the introduction of the mineralized water.

In the planned follow-up project ECO 3, this process is to be used for sustainable water restoration of the newly created open-cast mining lakes in Lusatia. Most of these lakes are currently characterized by increased acid input from the surrounding rock and very low pH values, which prevents both tourist and normal use of the water. Our limestone meal CO2 washing process makes it possible to supply the lakes with acid buffers, enable sustainable use and permanently bind CO2 as hydrogen carbonate.

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Lignite Brown Coal Research Development contract innovation update

Lignite Brown Coal Research Development contract innovation update

currently no new projects listed

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older Projects:

Optimization of the dynamic behavior of slewing mechanisms for bucket wheel excavators
Swivel mechanisms enable the targeted control of a rotary movement. This is between
two ball races arranged a plurality of rolling elements, which have a bearing function
of the rotatable system part. The slewing ring is driven by a
Pinion-ring gear system, whereby the drive power necessary for the rotary movement is over
several swivel drives arranged on the circumference of the ring gear are provided.
During the digging process, the bucket wheel excavator’s superstructure is lifted over the slewing mechanism
pivoted about its vertical axis, so that a large area of ​​the slope from the paddle wheel
can be covered without moving the device. However, due to the
mechanical coupling with the wheel arm, the digging forces in the slewing gear and in the
Swivel gear. Various process-specific effects contribute to the fact that the
The nominal loads of the digging and swiveling process are superimposed on dynamic loads. The
Dynamic additional loads limit the service life of those involved in the digging process
Machine elements, as every load cycle leads to partial damage to the components. In addition, will
the inherent behavior of the system is addressed, so that excess resonance occurs and
further promote component fatigue.
With the help of the simulation models to be developed, the overall system is coordinated
in terms of improved dynamics. As a suitable method of achieving this
The aim is to develop an optimized motor control for the swivel drives.
Linked to this is the analysis of the influence of the individual drive train components on
the dynamic behavior of the pan and dig process. This enables the delivering
SMEs integrate their partial deliveries into a coordinated system so that in

 

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Iron Steel Research Development contract innovation update

Iron Steel Research Development contract innovation update

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older Projects:

Co- ordination of EU- Funding is essential for maintaining international competitiveness

The steel industry will play a key role on the way to a climate-neutral economy in 2050. Since a significant part of the industrial CO2 emissions in steel production occurs via the blast furnace-converter route, the use of climate-friendly technologies could have an enormous impact on climate protection. Various possibilities are known and available for this, from the direct avoidance of CO2 in the production process (Carbon Direct Avoidance CDA) to the chemical processing of the CO2 (Carbon Capture and Usage CCU), to the circular economy. They must now be quickly researched in demonstration and pilot processes for their industrial feasibility. An even stronger focus on the circular economy offers further potential for more sustainability and climate protection.

Funding required for investment and operating costs
The conversion to green production processes is associated with massive investments for steel companies. For the locations in Germany, this will amount to around 30 billion euros by 2050. In addition, there are significantly higher operating costs for climate-friendly processes. The transformation therefore requires full funding of investment costs and additional operating costs in the case of large-scale implementation. On the part of the state, European and national funding programs exist or are being set up for which steel companies can apply.

It is also important that steel companies in Germany can apply for and receive funding from the ETS Innovation Fund, which is intended to support the implementation and demonstration of low-carbon steel production. This includes that companies using this program can receive additional funding from other funding programs (“sequencing”). In the 9th EU framework program for research and innovation and the achievement of the “Clean Steel” partnership, Germany should at least participate in proportion to its share in EU steel production.

 

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Glass Industry Research Development innovation update

Glass Industry Research Development innovation update

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older Projects:

Niels v. Bülow Foundation The foundation is named after Niels von Bülow (1894-1983), the chairman of the HVG and DGG from 1948 to 1963 and the initiator of the foundation. The foundation was set up in 1964 and came about thanks to a generous donation from Gerresheimer Glashüttenwerke, Düsseldorf. The sole purpose of the foundation is the non-profit promotion of vocational training and advanced training for young professionals for the glass industry. The aim is to give the scholarship holders the opportunity to study, to continue a course they have started, or to do a doctorate after completing their main examination through a one-off financial aid or financial aid extending over a longer period of time.

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