F R A U N H O F E R - I N S T I T U T E F O R L A R G E S T R U C T U R E S I N P R O D U C T I O N E N G I N E E R I N G I G P

ON OUR WAY INTO THE FUTURE

ANNUAL REPORT

2019

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ANNUAL REPORT 2019 ACTIVITIES AND RESULTS OF

FRAUNHOFER IGP

CONTENTS

4 Greeting

NEWS FROM FRAUNHOFER IGP

6 Overview of the institute

7 Factsandfigures

8 Organigram

9 FirstconstituentmeetingoftheFraunhoferIGPBoardofTrustees

10 Annual review 2019

12 Theinstituteisgrowing–fourthconstructionphase

14 TheFraunhoferIGPAward2019

COMPETENCES

16 JoiningandFormingbyPlasticDeformation

19 MechanicalJoiningTechnology

22 ThermalJoiningEngineering

25 NewMaterialsandProcesses

28 ProductionOrganisation

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3

31 AutomationEngineering

34 MeasuringofLargeStructures

MAJOR PROJECT

37 OWSplus–FloatingWindParks

CAREERS – JOIN US!

40 CareersatFraunhoferIGP

42 MariaSchur–Breakingdownstereotypes

44 MaximilianSchlicht:Oursimulatorspecialistforanysituation

46 DrMichaelIrmer–attheFraunhoferIGPsince2007

48 Associations, alliances and committee activities

50 Publications

56 Contacts

58 Sources/Imprint

Dear Readers and Friends of Fraunhofer IGP,

Iampleasedtowelcomeyouonceagaintoourcurrentannualreport.Theturbulenttimesofthe

pasthavenowsomewhatovershadowedthisreviewof2019,butwewouldliketoshowthatwe

arecontinuingtopursuetheissuesintheinterestsofourpartners.

Icanpromiseyouthatdespiteallthechangesineverydaylifeandespeciallytoworkingconditions

andpatterns,weatFraunhoferIGPwillcontinuetoprepare,developandadvanceexcitingtopics

sothattheycanbeimplementedinindustry.Thepresentreportwillprovidesomeexamplesand

actasacatalystinplaces.Forexample,wehavenotbeenabletocelebrateappropriatelythegood

newsreceivedattheendof2019thatwehavebeengrantedinstitutestatusasof1Januarythis

year.Wehavealsohadtocancelthetopping-outceremonyforournewbuilding,butworkis

proceeding–andonscheduletoo!Itisasymbolthatwewillcontinuetostayontheballand

constantlyembracenewchallenges.

Weshallindeedholdacelebrationatasuitabletime,becauseevenwithallthereports,techno-

logymustalsobefullyappreciatedtobeunderstoodandwearekeennottodenyyouthisop-

portunity.Wehaveonceagainputtogetheranew‚bouquet‘ofprojectsandtopicsinthisreport

togiveyouanimpressionofhowdiverseandcomplexoursolutionstoyourchallengescanbe.

Wearealsointroducingyoutosomeofthepeoplebehindtheprojects,becauseweknowthat

theyareresponsiblefordirectingtheresultsandthequalityofourprojects.Youshouldusethis

reportasasourceofinspirationfortomorrow‘sinnovations.Aboveall,stayhealthy,sothatwe

cancontinuetodriveforwardkeyissuestogetherinthefuture.

Welookforwardtodiscussionswithyou!

WithkindregardsfromtheHanseaticand

UniversityCityofRostock,

Prof.Dr.-Ing.WilkoFlügge

DirectorFraunhoferIGP

4

GREETING

Prof. Dr-Ing. Wilko Flügge,

Director of the Fraunhofer

Institute for Large Structures in

Production Engineering IGP.

Image: Fraunhofer IGP Rostock

Institute Director Prof. Wilko Flügge (left) and De-

puty Director Prof. Knuth-Michael Henkel on site at

the fourth construction phase of Fraunhofer IGP.

Image: Fraunhofer IGP Rostock

5

Toaddress thesechallenges,aprojectgroupwas founded in

Rostockin1992bytheFraunhoferInstituteforManufacturing

EngineeringandAutomationIPA.In2017,thisgroupbecame

the independent Fraunhofer Institute for Large Structures in

ProductionEngineeringIGP,whichhasofficiallybeenaninstitu-

teoftheFraunhoferSocietysince2020.

Thescientistsprimarilyspecialiseinfindingalternativesthatre-

ducetheburdenontheenvironmentandworkers.Theaimof

theirresearchistodevelopholisticsolutionsthatenablemore

cost-effectiveandhigh-qualityproduction.

Strong research partner in north-east Germany

„Resource-savingsolutionsforspecialistproductionchallenges

areacrucialcomponentincentralindustrialsectorsinGermany

andEurope“,explainsProf.ReimundNeugebauer,Presidentof

What will innovative production of large structures look

like in the future? The Fraunhofer Institute for Large

Structures in Production Engineering IGP in Rostock is

conducting research into this. The institute develops in-

novative concepts for product and process innovations.

The research focus is on future-oriented industries such

as shipbuilding and steel construction, energy and en-

vironmental technology, rail and commercial vehicle ma-

nufacturing as well as mechanical and plant engineering.

The formerly independent research group was made into

a Fraunhofer Institute at the beginning of 2020 and is

now the first institute of the Fraunhofer Society to be

headquartered in Mecklenburg-Western Pomerania. The

decision behind this move was taken on 22 October 22

2019 at a meeting of the Executive Board of the Fraun-

hofer Society. Increasinglylargeandmorecomplexstructures

havetowithstandextrememechanicalandclimaticstresses.

RESEARCH FACILITY BECOMES INSTITUTE

6

Fraunhofer IGP in the south of Rostock is expanding further. Image: Fraunhofer IGP Rostock

OVERVIEW OF THE INSTITUTE

7

the Fraunhofer Society, on the foundingof the institute, ad-

ding: „With the opening of the Fraunhofer IGP, Germany is

taking a leadingposition in the development of efficient lar-

ge-scale structures in production – a decisive contribution to

makingindustrialvaluechainssustainableandfuture-proofver-

susinternationalcompetition.“

ThenumberofemployeesattheInstitutecontinuestorisestea-

dily.Theresearchfacilityiscurrentlybeingexpandedinafourth

constructionphase to includeaproductionhallwith laband

officespace.“Wehavebeenareliableandstrongresearchpart-

nerofindustryinMecklenburg-WesternPomeraniaandbeyond

formany years. In thepast two yearswehavebeen able to

further expandour cooperation.Wewill continue to actively

applyourexpertiseinthefieldoflargestructuresinthefuture”,

saysInstituteDirector,Prof.WilkoFlügge.

In the new Fraunhofer IGP building, scheduled for completi-

on in2021, the future topic“Shipyard4.0”willbe in focus.

Amongotheraspects,theInstitutehasspecialisedinresearch

onproductiontechnologyandprocesses,aswellasonmateri-

alssubsea.AsamemberoftheSmartOceanTechnologyrese-

archgroup,FraunhoferIGPwillalsoberepresentedintheDigital

OceanLab.Amongotherprojects,theIGPiscurrentlyinvolved

O V E R V I E W O F T H E I N S T I T U T E | F A C T S & F I G U R E S

Number of employees

Income 2019

Total Budget

EUR million

9.8

8.7

7.2

6.7

Scientific assistants and apprentices

University staff

Technical and administrative staff

Scientists

Public, EU and other income Business income

Institutional funding

1

8

inthecoredevelopmentoftheGermanMinistryofEducation

andResearch„OWSplus - FloatingOffshoreWindSolutions“

project.Here,thealliancepartnersaredevelopingsolutionsfor

thenextevolutionarystageofregenerativepowergeneration.

Employee numbers

In 2019, the total number of staff employed at Fraunhofer

IGProseto205,withthemajorityofourscientistsholdinga

degree in engineeringor industrial engineering. Theworkof

the Fraunhofer team is supportedbya total of109 research

assistantsand,asinthepreviousyears,theteamwillbejoined

bythreetrainees.Incooperationwiththechairsofmanufactu-

ringtechnologyandjoiningengineering,sevenuniversityem-

O V E R V I E W O F T H E I N S T I T U T E | F A C T S & F I G U R E S

ployeesworkcloselywithFraunhoferIGPinbothresearchand

education.

Earnings and total budget

Earningsfor2019amountedtoatotalofEUR9.8million.With

economicreturnsof50%,budgettargetswerealsoonceagain

achieved in 2019. The Fraunhofer Institute in Rostock also

maintainedabalancedbudget in2019,withapositivecarry-

over.Theoverallbudgetcontinuedtoshowsteadygrowth.

ORGANIGRAM OF THE FRAUNHOFER INSTITUTE FOR LARGE STRUCTURES IN PRODUCTION ENGINEERING IGP

As at: July 2020

Director Deputy Director

Prof.Dr.Ing. Prof.Dr.-Ing.habil.

WilkoFlügge Knuth-MichaelHenkel

Institute assistants

Dipl-Ing. SabineWegener

VirginieRogge

Senior Professor

Prof.Dr.-Ing.

Martin-ChristophWanner

Teaching

Dr.-Ing.UlrichKothe

Technical Services

Dipl.-Ing.KayMüller

Accredited Test Labo-

ratory

M.Eng.HolgerBrauns

Inspection, Monitoring and Certification Body according to LBOProf.Dr.-Ing.RalfGlienke

Administration

M.Eng.LisaKnaack

New Materials and

Processes

Dr.-Ing.NikolaiGlück

Production Systems

and Logistics

Dr.-Ing.JanSender

Manufacturing

Technology

Prof.Knuth-MichaelHenkel

Production

Organisation

Dr.-Ing.JanSender

Adhesive Bonding

Technology

M.Sc.LindaFröck

Joining and Forming

by Plastic Deformation

M.Sc.PascalFroitzheim

IT Services

Dipl.-Wirt.-Ing.

MarcusBaier

Public Relations

Mag.SilkeSchulz

Automation

Engineering

Dipl.-Ing.SteffenDryba

Fibre Composite

Technology

Dipl.-Ing.StefanSchmidt

Mechanical Joining

Technology

Dipl.-Ing.MaikDörre

Thermal Joining

Engineering

Dr.-Ing.AndreasGericke

Coating, Weathering

and Corrosion Protection

Dr.-Ing.MichaelIrmer

Measuring of

Large Structures

Dr.-Ing.MichaelGeist

Quality Management

MariettaFlügge

9

2

BOARD OF TRUSTEES

FIRST CONSTITUENT MEETING OF THE FRAUNHOFER IGP BOARD OF TRUSTEES

Fraunhofer IGP has been an independent research group

since 2017 and an institute since 2020. Within the Fraun-

hofer Society, the Board of Trustees supports the institute

directors and the executive board with help and advice. It

includes representatives from the worlds of science, bu-

siness and politics. On 21 May 2019, the Fraunhofer IGP

Board of Trustees met for the first time.

Inthisfirstmeeting,themembersofthenewBoardwereap-

pointed.DrJohannesLandes,asrepresentativeoftheExecutive

BoardoftheFraunhoferSociety,handedoverthecertificatesof

appointmenttoallthosenominated.TheyincludeDrAndreas

Dikow(WebastoSE),HaraldJaekel(PeeneWerft),UlfMaude-

rer(BusinessAssociationofMecklenburg-WesternPomerania),

Prof.DrMarionMerklein (University of Erlangen),GeorgMi-

chels(SalzgitterAG),DrThomasKühmstedt(OstseestaalGmbH

&Co.KG),Prof.DrWolfgangSchareck(RectoroftheUniversity

ofRostock),RalfSvoboda(MinistryofEconomicsM-V),Holger

Wandsleb(MinistryofEducationofMecklenburg-WesternPo-

merania),DrJohannesLandesandDrHendrikGorzawskifrom

theFraunhoferSocietyaswellasInstituteDirectorProf.DrWil-

koFlügge.

ThefirstofficialactofthenewlyappointedBoardwastheelec-

tionofachairman.DrThomasKühmstedtfromthecompany

Ostseestaalwaselectedunanimously.

Inthesessionthatfollowed,InstituteDirectorProf.Flüggegave

anoverviewofthecurrentsituationoftheresearchfacility.To-

getherwithProf.Schareck,hepresentedvariouscoreelements

ofafutureOceanTechnologyCampusprojectinwhichFraun-

hoferIGPwillparticipate.Amongotheraspects,FraunhoferIGP

will focus on the areas of subseawelding, bonding and3-D

1 The participants and members of the then newly founded Board

of Trustees from the left: Ulf Mauderer, Holger Wandsleb, Ralf Svo-

boda, Harald Jaekel, Dr Andreas Dikow, Dr Thomas Kühmstedt, Prof.

Wolfgang Schareck, Prof. Marion Merklein, Georg Michels, Prof. Wil-

ko Flügge as well as Dr Hendrik Gorzawski and Dr Johannes Landes.

Image: Fraunhofer IGP

surveying.EngineersfromIGPwerealsogiventheopportunity

topresenttheirprojectworkatthemeeting.PascalFroitzheim,

GroupHeadofJoiningandFormingbyPlasticDeformation,pre-

sentedtheprojectfortheDevelopmentofaHandlingSystem

forAutomatedColdPlasticForming.Theresearchisbeingcon-

ductedinconjunctionwiththemetalprocessingcompanyOst-

seestaalandtheUniversityofRostock.FrederikSchmatzfrom

ProductionOrganisation group introduced the Human-Robot

CollaborationinAircraftStructureAssemblyproject.

Both these projects underpin the previously agreed direction

oftheresearchinstitution.Prof.FlüggehighlightedFraunhofer

IGP‘sUSPs.TheBoardofTrusteesfurtherapprovedhispropo-

sedfocusonproductiontechnologyfor largestructures,with

particular reference to shipbuilding.At thisfirstmeeting, the

Board of Trustees recommended the Executive Board of the

FraunhoferSocietytograntinstitutestatusassoonaspossib-

le.Thisrecommendationwasimplemented,withtheExecutive

Boardresolvingatameetingon22October,2019that,asof

1January2020,FraunhoferIGPwouldbecomethefirstFraun-

hoferInstituteheadquarteredinMecklenburg-WesternPome-

rania.

1

10

ANNUAL REVIEW 2019

Inmid-June,alltheinstitutesinvolvedinthenewFraunhofer@

SubseaconsortiummetatFraunhoferIGPtodiscusskeypoints

for the further development of joint projects and collabora-

tions.Besides the IGPand IGDfromRostock, the IOSB, IKTS,

IZMandIBTMarealsoinvolved.Amongothertopicsdiscussed

bytheparticipantsweresynergyeffectsthatmightbeachieved

bytheinstitutionsandpotentialcommonresearchtopics.After

themeeting,theparticipantsinvolvedintheOceanTechnology

Campusmettodiscussfurtherplans.

On 12August 2019, Prof.Wilko Flügge and his deputy Prof.

Knuth-MichaelHenkelreceivedadistinguishedvisitorattheIn-

stitute.Prof.ReimundNeugebauer,PresidentoftheFraunhofer

Society,participated inthe15thBusinessSail,anevent that is

partoftheHanseSailmaritimefestival.Togetherwithcompanies

fromtheregionandtheresearchinstitutionsoftheFraunhofer

Society, thegreen lightwasgiven for the„OceanTechnology

CampusRostock“,whichisbeingbuiltintheFischereihafendis-

trictofRostock.BeforeProf.Neugebauercontinuedhisjourney

onMonday,hewasguidedthroughthefacilitybyProf.Flügge

andinformedaboutthestatusofthefourthconstructionphase.

FraunhoferIGPmadeitsdebutatNEVA,theRussiantradefair,

whichtookplacefrom17-20SeptemberinSt.Petersburg.NEVA

is a trade fair and conference for shipbuilding, shipping and

offshoretechnologyaswellasbeingthelargestforumofitskind

inRussia.Thescientistspresentedtheachievementsandcurrent

statusofresearchattheInstitute.Prof.WilkoFlüggegavealec-

tureon„Industrialmaritimeresearch“inthecontextofawork-

shop.FraunhoferIGPandtheparticipatingcompaniesusedthe

opportunityoftheeventtodrawattentiontotheadvantagesof

Mecklenburg-WesternPomeraniaasastrongbusinesslocation.

SUBSEA@FRAUNHOFER – JUNE MEETING AT THE INSTITUTE

VISIT FROM THE PRESIDENT OF THE FRAUNHOFER SOICETY

FIRST APPEARANCE AT THE NEVA TRADE FAIR IN ST. PETERSBURG

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FRAUNHOFER IGP HOSTS 46TH ROSTOCK CHAMBER OF COMMERCE TECH EVENING

NØRD – MVS FIRST DIGITAL CONGRESS HOSTED BY FRAUNHOFER IGP

FINNISH DELEGATION VISITS THE ROSTOCK RESEARCHERS

About70interestedvisitorscametotheInstituteforaneventon

“Value creation inMecklenburg-Western Pomerania – Robotics

inindustrialapplications”.Beforespeakerstookthestandon24

September,guestsweretakenonatouroftheresearchfacility.Dr

JanSenderfromFraunhoferIGPgaveanoverviewofthe„Status

QuoandTrendsinRobotics“.DrLarsGreitschfromMMGMeck-

lenburgerMetallgussGmbH,TorstenLüskowfromHanseaticRohr

GmbH,NormanNieland fromHolz EggerWismarandAndreas

SchroederfromS.K.M. InformatikGmbHexplainedtheareasof

applicationforroboticsintheircompanies.

Afullprogrammewaspresentedon7NovemberattheRostock

research facility. The first Digital Congress M-Vs took place

among other events at Fraunhofer IGP. One of the keynote

speakerswasDrHolgerHeynfromVolkswagenAG.Theevent

kickedoffwithadigitalgreetingfromMinister-President,Manu-

elaSchwesig.ChristianPegel,MinisterforEnergy,Infrastructure

andDigitisation inMecklenburg-Western Pomerania, put in a

personalappearance.Forawholeday,visitorswereabletoat-

tendpresentationsandworkshopstofindouthowthestateof

Mecklenburg-WesternPomeraniaisdrivingforwarddigitisation

andthegoalsthathavealreadybeenachieved.

InNovember,theRostockscientistsofFraunhoferIGPreceiveda

delegationfromTurku,Finland.Dr-Ing.AlexanderZychhadrepre-

sentedtheIGPattheFraunhoferDayinTurkuinSeptember,where

hemethisFinnishcolleaguesandwithoutfurtherado,areturn

visit toRostockwasarrangedforNovember.Amongtheguests

wererepresentativesofthecityadministrationofTurku,TurkuUni-

versityofAppliedSciencesandtheMachineTechnologyCenter.

Thecityrepresentativesaswellasthosefromindustryandscience

showedgreatinterestinfurtherexpandingthecooperationwith

Fraunhofer–includinginRostock.

THE INSTITUTE IS GROWING FOURTH CONSTRUCTION PHASE

1 & 2: Professors Wilko Flügge (left) and Knuth-Michael Henkel

visit the construction site to see how the fourth construction phase

project is progressing. Images: Fraunhofer IGP

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13

The foundation stone for today‘s Fraunhofer IGP was laid in

Rostockin1992.Atthattime,thescientistsbegantheirworkas

theRostockprojectgroupoftheFraunhoferIPA(FraunhoferIns-

tituteforManufacturingEngineeringandAutomationIPA,Stutt-

gart) inWarnemünde. Since 2004, the facility on the science

campusinRostocksouthhasgrowninanumberofconstruction

phasestomorethan6,000m2oflabandofficespace.

Another2,000m2willbeadded.InMarch2019,workbegan

onthefourthphaseofconstruction.Newoffices, laboratories

andafurthertestinghallarebeingbuiltdirectlynexttotheexis-

ting building. The investment volume for the newbuilding is

aroundEUR14million.

InstituteDirectorProf.WilkoFlüggeexplains:„Inournewbuil-

ding the Shipyard 4.0 projectwill set a new focus.We have

grownsofast inrecentyearsthatweurgentlyneedtheaddi-

tionalspace,notjustsothatwehavemorespaceforourcons-

tantlygrowingteam,butalsosothatwecanworkevenmore

successfully and intensivelywith our partners in industry. The

newworkshopenablesus tocommissionand testequipment

fortheproductionoflargestructuresinactualscaledimensions.

A fast-motionvideoclipof the constructionprogress in2019

canbeviewedonlineat:

https://bit.ly/38vsoTp

OrsimplyscantheQRcodetowatch!

T H E I N S T I T U T E I S G R O W I N G – F O U R T H C O N S T R U C T I O N P H A S E

FRAUNHOFER IGP HEADING TO THE FUTURE – WITH NEW FACILITIES AND FOURTH CONSTRUCTION PHASE

2

The existing building is on the left. This was built in three construction phases between 2004 and 2013. The construction work for the fourth

phase, which can be seen on the right of this image, began in March 2019 and is provisionally scheduled for completion in spring 2021.

Image: Fraunhofer IGP

14

Since 2018, the Fraunhofer Institute for Large Structures in

Production Engineering has presented the Fraunhofer IGP

award. In this, the second year, the award went to Ostsee-

staal GmbH & Co KG. In cooperation with the scientists of

the Fraunhofer IGP, the Stralsund-based company is in char-

ge of the HakU project for the automation of a producti-

on process that previously relied on the experience of the

plant operator. „We see this award as a future and innovation

prize.Ouraimistohighlightthetechnological,economic,ecolo-

gicalandsocialbenefitthatisgainedthroughtheclosecoopera-

tionbetweentheresearchinstitutionanditsindustrialpartners“,

saysProf.WilkoFlügge, InstituteDirectorofFraunhofer IGP, in

describingtheaward.

The HakU project

Since2016,FraunhoferIGPhasbeenworkingtogetherwithOst-

seestaalandtheUniversityofRostockinaprojecttodevelopa

handlingsystemforautomatedcoldplasticforming(HakU).The

THE FRAUNHOFER IGP AWARD 2019

THE FRAUNHOFER IGP AWARD 2019 – FUTURE AND INNOVATION AWARD GOES TO OSTSEESTAAL IN STRALSUND

three-dimensionalformingofheavyplatesforshipbuilding,fas-

ciaconstruction,mouldconstructionandthefieldofrenewable

energiesalldependonamulti-stagecoldplasticformingprocess

whichfacilitatesfreebending.Thepositioningoftheheavypla-

tesishandledbyacranesystem.Controloftheprocessiscont-

ingentontheexperienceandpurelysubjectiveassessmentofthe

plantoperator.Toincreasetheefficiencyoftheprocessandto

archivetheexperienceofplantoperators,scientistsatFraunhofer

IGP,theUniversityofRostockandtheemployeesofOstseestaal

areworkingonautomatingthishandlingsystem.

Award winners 2019 – Ostseestaal from Stralsund

“Theexcitingthingaboutthisprojectisthetransferofthepurely

subjectiveperceptionoftheplantoperatorintoanobjective,cal-

culableandautomatedprocesscontrol.Wecanadaptsomeof

theresultsforotherproductionplants.Allinall,thiswillreduce

throughputtimesandsaveproductioncosts.Energyconsumpti-

onisreduced,sinceanumberofproductionstepsarenolonger

necessary,makingmanufacturingsomuchmoreefficient.With

thisproject,OstseestaalishelpingtoenhanceStralsundasabu-

siness locationandtheGermanstateofMecklenburg-Western

Pomeraniaasasupplier tothemaritime industry,aviationand

energysector“,explainsProf.Flügge.

„We appreciate the highly effective cooperation with Ostsee-

staal.InProjectManagerHarrySchellhorn,Ihaveacontactwho

supportsuswithagreatdealofexperienceandexpertiseinthe

field of automation and cold plastic forming.We are pleased

with the trust, the courageand thewillingnessofOstseestaal

tomoderniseanintegratedproductionsystemduringoperation.

Questionsarisingcanbeaddressedopenlyanddirectlyonboth

sides.Thismakesiteasiertoworkquicklyandpurposefullyon

solutionsandtoremedythemanysmall‚teethingproblems‘in

suchacomplexplant,“saysPascalFroitzheim.

(l to r) Harry Schellhorn and Maximilian Müller from Ostseestaal

with Tobias Handreg and Pascal Froitzheim. Image: Fraunhofer IGP

h t t p s : / / b i t . l y / 2 V h l W n m

COMPETENCES

15

M A N U F A C T U R I N G T E C H N O L O G Y

G R O U P S :J o i n i n g a n d F o r m i n g b y P l a s t i c D e f o r m a t i o n

M e c h a n i c a l J o i n i n g Te c h n o l o g yT h e r m a l J o i n i n g E n g i n e e r i n g

N E W M A T E R I A L S A N D P R O C E S S E S

T E A M S :A d h e s i v e B o n d i n g Te c h n o l o g y

F i b r e C o m p o s i t e Te c h n o l o g yC o a t i n g , W e a t h e r i n g a n d C o r r o s i o n P r o t e c t i o n

P R O D U C T I O N S Y S R T E M S A N D L O G I S T I C S

G R O U P S :P r o d u c t i o n O r g a n i s a t i o nA u t o m a t i o n E n g i n e e r i n g

M e a s u r i n g o f L a r g e S t r u c t u r e s

JOINING AND FORMING BY PLASTIC DEFORMATION

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J O I N I N G A N D F O R M I N G B Y P L A S T I C D E F O R M A T I O N | O V E R V I E W

JOINING AND FORMING BY PLASTIC DEFORMATION

Thefocusoftheresearchinjoiningbydeformationisonques-

tionsrelatingtothejoiningoflightweightconstructionmateri-

als,suchasfibrereinforcedplasticsorwroughtaluminiumalloys

bothasjointsusingpurelydeformationandincombinationwith

adhesivebonding.Themainfieldsofapplicationforthejoining

methodsinquestionarewithinthemobilitysector(aircraft,rail

andautomotiveindustries).

The research coversboth the initial qualificationof thedefor-

mationor settingprocessof the joint and the analysis of the

load-bearingcapacityofthejointunderstaticandcyclicloading

and in theeventofa crash.Aparticular focushere ison the

fracture-mechanicalevaluationofthejointswithrespecttocrack

initiation,crackpropagationandfracturebehaviour.Furthermo-

re,thepropertiesofthejointsareanalysedovertheservicelife,

andtopicssuchascorrosionresistance,leaktightness,electrical

conductivityorthepossibilitiesof(non-destructive)testing(NDT)

areexamined.

The focusof the research into formingbyplasticdeformation

centresonfundamentalquestionsofforminganddeformation

ofcomponentstructures.Themainemphasishereisonthede-

velopmentofpredictionmodelsand thederivationofprocess

controlconceptsforcoldandhotplasticforming,predominantly

for the formingof large steelplateswithmaterial thicknesses

ofmorethan5mm.Thesehavetobeevaluatedandoptimised

withrespecttotheirreal-timecapabilityforintegrationintoma-

chinecontrolsystems.

.

This is new:

Thegroup‘smachineryhasbeenexpandedtoincludea100kN

forming press for experimental testing and sampling of new

typesofjoiningandformingprocesses.

Group Head

M.Sc.PascalFroitzheim

Tel.+4938149682-228

pascal.froitzheim@igp.fraunhofer.de

ACTIVITIES

• Application-specificdevelopmentandoptimisationofde-

formation joining processes of lightweight construction

materials

• Processintegrationofjoiningbydeformationthroughin-

novativesettingdeviceconceptsandergonomicworkpla-

cedesign

• Establishmentofqualityassuranceprocedures,forexamp-

lebymonitoringthesettingprocessorbyNDTmethods

• Materialandjoiningtestingundermechanicalload(static,

cyclic,mechanicalcracking)

• Forming of heavy plates and development of simplified

predictivemodelsfortechnicalcontrolintegration

• Developmentofself-learningsystemsforjoiningandfor-

mingbyplasticdeformationprocesses(AI)

• Processsimulationduringjoiningandformingbymeansof

numericalFEM(ANSYS,LS-Dyna,etc.)

• Analysismethodsforsensitivityanddamageanalysisdu-

ringjoiningandforming(materialandmetallography)

J O I N I N G A N D F O R M I N G B Y P L A S T I C D E F O R M A T I O N | P R O J E C T S

18

Duetotheirefficiency,deformationjoiningprocessesrequiringno

pre-holingareincreasinglyusedinthemobilitysector.Thefocus

isonprocessesthatdonotrequiretheuseofanauxiliaryjoining

part,suchasclinching.Thereiscurrentlyanacceptanceproblem

inthefieldofaircraftconstruction,duetoalackofknowledgeon

thefailure-behaviourofclinchconnectionsundercyclicloading.

Theaimoftheresearchprojectisthereforethedetailedanalysisof

crack initiationon clinch connectionsand thepredictionof the

cracklocationandremainingservicelifeoftheseconnections.A

centraltaskistodemonstratetheimpactoffriction-basedcrack

initiationonthefailurebehaviourofclinchconnections.

Forfurtherdetailsonthisproject,pleasesee:

https://www.igp.fraunhofer.de/en.html

Theindustrialrollbendingofheavyplatesinsmallbatchesiscur-

rentlycontrolledexclusivelymanually.Thishastheconsequence

thattheefficiencyandeconomyoftheformingprocessisdepen-

dent on the experience of the system operator. Consequently,

inorder tooptimise theprocess,anobjective real-time-enabled

controlapproachbasedonasimplifiedsubstitutemodelisbeing

developedinthecontextoftheresearchproject.Withthehelpof

experimentalandnumericalinvestigationsplusasensitivityanaly-

sisoftheinfluencingfactors,thesubstitutemodelcanbespecifi-

callyadaptedforindustriallyrelevantspaceparameters.Usingthe

substitutemodelleadstoasustainableimprovementincontrolof

therollbendingprocess,especiallyforSMEs.

Forfurtherdetailsonthisproject,pleasesee:

https://www.igp.fraunhofer.de/en.html

Production-relatedfluctuationsincomponent

productionleadtoincreasinglysmallertolerance

zones in theproductionprocessandtherefore

tohighercosts.Thenetworkingofproduction

data for individual production steps is insuffi-

cient and correlations between these data are

unknown.

Itthereforealsofollowsthatthepotentialforexpan-

dingthetolerancerange isalsounknown.Theaimof this

researchprojectistheanalysisandnetworkingoftheproduction

stepsofaselectedproductonthebasisofthepro-

ductiondata.

To achieve this, experimental and numerical

analyses are carried out along the production

chain. The production data are first subjected

to a sensitivity analysis and then the correlati-

on between production steps is analysed. In this

way, tolerance specifications can be extended and

costsreduced.Forfurtherdetailsonthisproject,pleasesee:

https://www.igp.fraunhofer.de/en.html

FRICTION-BASED CRACK INITIATION – AT WHAT POINT DOES THE CLINCH JOINT FAIL?

SIMPLIFIED REPLACEMENT MODEL FOR PROCESS CONTROL FOR ROLL BENDING LARGE SHEET THICKNESSES

CONCEPTION OF AN ADAPTIVE PROCESS CHAIN FOR MECHANICAL JOINING

Forming

Joining

Stretching

MECHANICAL JOINING TECHNOLOGY

19

M E C H A N I C A L J O I N I N G T E C H N O L O G Y | O V E R V I E W

20

MECHANICAL JOINING TECHNOLOGY

Growingdemandsonthemanufactureofenergyandresour-

ceefficientproductsandenvironmentalaspectsareleadingin

manybranchestoanincreasinguseoflightweightconstruction

concepts.Theassociateduseofnewtypesofmaterialhasgiven

risetoarenaissanceinparticularofmechanicaljoiningtechno-

logiesinrecentyears.Inordertogivedueconsiderationtothis

development,theFraunhoferIGPisdevelopinginnovativeand

cost-effectivesolutionstotheassociatedproblems.

Thefieldofmechanicaljoiningtechnologyinvolvesvariousre-

searchfocusesinlightalloyandsteelconstruction,inrailvehic-

leconstructionandingeneralmotorvehicleandmachineen-

gineering.Weelaboratebranch-specificsolutionstogetherwith

ourclients.Therightchoiceandcommandofthejoiningme-

thodsgoalongwaytodeterminingthefunctionality,reliability

andsafetyofaconstructionrightfromthestartoftheproduct

development.Atthesametime,theoptimumjoiningtechnolo-

gyfortheparticularapplicationhelpstosavecostsandmaterial

duringproductionanduse.Thescopeofactivitiesextendsfrom

theadviceonthechoiceoftheoptimumjoiningtechnologies

through theanalysisof the load-bearingstrength rightup to

thederivationofsuitabledimensioningrules,dependingonthe

demandsoftheparticularapplication.

The theoretical considerations are supported by the accredi-

tedtest laboratoryoftheFraunhofer IGPthat,withthemost

modern testing technology, is able tocarryoutextensiveex-

perimentalstudiesintomaterials,fasteners,jointsandcoating

systemsunderstandardisedconditions.

This is new:

SinceMay2020,M.Sc.MaikDörrehasbeenGroupHeadof

Mechanical Joining Technology. He has been employed at

Fraunhofer IGPsince2015andhadalreadyworkedasastu-

dentassistantattheinstitutebeforethat.DrChristianDenkert

successfully completedhisPhDwithdistinctiononDecember

9,2019.MaikDörreandMatthiasSchwarzhavebothsuccess-

fullycompletedtheiradvancedtrainingasspecialistfastening

engineers.

Group Head

Dipl.-Ing.MaikDörre

Tel.+4938149682-239

maik.doerre@igp.fraunhofer.de

ACTIVITIES

• Consultingoncurrenttrendsanddevelopmentsinjoining

technology(screws,rivets,lockbolts,blindfasteners,fun-

ctionalcarriers/elements)

• Preparationof expert opinions and testing concepts for

connections in light metal alloy and steel construction

(ZiE,abZ/abG,ETA)

• Determinationof static frictioncoefficientsaccording to

DINEN1090-2appendixGandTL/TP-KORsteelstructures

• Numerical simulation (FEM) with parameterised model

building

• Investigationofthefatiguestrengthofmaterialsandfas-

tenersaccordingtoDIN50100andDIN969

• WöhlertestsforthedeterminationofFATclassificationsin

linewithDINEN1993-1-9andFKMguidelines

• Developmentofmeasuringalgorithmsandtestmethods

fornon-regulatedjoiningprocesses

• Derivationofmaintenanceconcepts frompreload-force-

timebehaviour(„mechanicalmaintenance-free“)

• Performance of torque/tension force tests according to

DINENISO16047

• Seminarsonthecalculationofboltedjointsaccordingto

DINEN1993-1-8and9(Eurocode3)andVDI2230(Part

1)

• Certification/external

monitoring of building

product manufacturers

in the capacity of of-

ficially recognised test

station in accordance

with the German state

buildingregulations.

M E C H A N I C A L J O I N I N G T E C H N O L O G Y | P R O J E C T S

21

Slip-resistantboltedconnectionsshallbeusedwherevertheme-

chanical jointsaresubjectedtoimpact,vibrationand/orloadre-

versaltopreventeffectivelymovementoftheconnectedpartsif

loadedmainlyinshear.

The load-bearingcapacity isactivatedby friction that isa result

fromthepreloadoftheboltandtheslipfactorµintheslipplanes.

Commonly,theslipfactorsthatcanbeachievedfortypicallyan-

ti-corrosioncoatingsinsteelstructurearelowdespitethecomplex

pre-treatmentofthefayingsurfaces.Byapplyingasuitablestruc-

turaladhesiveontheslipplanes,significantlyhigherslipfactorand

consequently,increasesinloadcapacity,canbeachieved.Aspart

oftheongoingresearchproject,thecombinationofslip-resistant

connectionsandstructuraladhesivesareunderdeepInvestigation.

Forfurtherdetailsonthisproject,pleasesee:

https://www.igp.fraunhofer.de/en.html

For fastening attachments in „thin-walled“ sheetmetal struc-

tures,functionalelementsinsertedbyformingtechnologyoffer

anextremelyeconomicalalternativetoweldedbushings.Inad-

ditiontothestaticstrengthandtheload-bearingcapacityunder

crashloads,theirfatigueresistanceisalwaysarelevantissue.The

researchprojectaimstogenerateamethodofprovingfatigue

resistancebymeansofusingthelocalstresstheoryforsheetme-

talsectionsinfluencedbyformingtechnology.Thatforexample

occurasaresultofaprocesssequenceduringtheinsertionof

functionalelement.Thelocalstresstheoryisalsocomparedwith

thenominalS-Ncurvesofthedetailcategoryexaminedonthe

formedsheetmetalsectioninS-N-Tests.

Forfurtherdetailsonthisproject,pleasesee:

https://www.igp.fraunhofer.de/en.html

Inthefieldofsteelandlight-

weight metal construction,

therehasbeenatrendtothe

useofhigh-strengthsteels in

recentyears.Overtime,these

constructionsaresubjectedto

predominantly(static)andnot

predominantly(fatigue)loads.

Theuseofblindrivetingtech-

nology in theseconstructions

raisesquestions from the structural engineer‘spointof view,

whichareaddressedinthecurrentresearchprojectsatFraun-

hofer IGP.Theaimisthedevelopmentofdesignrules,which

considerthehighermaterialstrengthsalreadyduringplanning

stage.Withthesedesignconceptsamoreeconomicaldesign

shouldbepossible.

Forfurtherdetailsonthisproject,pleasesee:

https://www.igp.fraunhofer.de/en.html

RE-STRESSED HYBRID CONNECTIONS WITH LOCKBOLTS & HIGH-STRENGTH BOLTS

VIBRATION RESISTANCE BY PRESSING-IN SHEET METAL SECTIONS

EXPANSION OF THE APPLICATION LIMITS OF BLIND FASTENERS FOR CONNECTING HIGH STRENGTH MARTERIALS

THERMAL JOINING ENGINEERING

22

23

T H E R M A L J O I N I N G E N G I N E E R I N G | O V E R V I E W

THERMAL JOINING ENGINEERING

Thermalcutting,coatingandjoiningprocessesplayacentralrole

as value-addedandquality determiningmanufacturing steps in

a largenumberofproductionprocesses. Inhighly industrialised

branches,weldedjointsandweldingprocesses,inparticular,have

tosatisfyconstantlygrowingandchangingdemandswithrespect

tocost-effectiveness,flexibilityandquality.Theseinclude,forex-

ample, high-quality processing ofmodernmaterials with often

high demands on themechanical and technological properties

withconsistentprocessreliability,theassuranceofthepartinte-

grityofweldedcomponentsofinnovativelightweightsteelcon-

structionssubjecttohighstaticandcyclicloads,increasesinthe

cost-effectivenessofweldingprocessesthroughmodernautoma-

tionsolutions,andtheintroductionofhighlyproductivewelding

methodstoincreasecompetitivenessasananswertothegrowing

pressureofcostsinglobalisedmarkets.

Inordertofindlong-termandsustainablesolutionstotheresul-

tingtechnologicalandeconomicchallenges,theThermalJoining

EngineeringgroupatFraunhoferIGPiscontinuouslyengagedin

innovativeresearchanddevelopmentoncurrentandfutureissues

in thefieldsof shipbuilding, structural steelwork, onshore and

offshore wind energy. We always strive to holistically evaluate

technological,metallurgicalanddesignaspectsoftherespective

weldingapplicationswithinthevalue-addedchain.

This is new:

Thegrouphaschanged itsname.WeldingEngineeringhasbe-

comeThermalJoiningEngineering.GroupHeadDr-IngAndreas

Gerickeexplains:„Thechangeofnamewasnecessarytocommu-

nicateandrepresentourcoreareaofweldingtechnologyaswell

asourotherskillsintheareaofsolderingandthermalspraying,

whichhavegrownsustainablyandsuccessfullyovertheyears.In

thisway,weaimtobemorevisibletopotentialcustomersand

continuestrategicgrowthintheseareas”.

Group Head

Dr-Ing.AndreasGericke

Tel.+4938149682-37

andreas.gericke@igp.fraunhofer.de

ACTIVITIES

• Application-oriented development and optimisation of

thermaljoining,cuttingandcoatingprocesses

• Determination of mechanical-technological and frac-

ture-mechanicalmaterial,jointandcomponentproperties

• Analysisofweldingprocessesbycombinedoptical,electri-

calandthermalmeasuringmethods

• Developmentandqualificationofeconomicalmethodsfor

improvingthefatiguestrengthofweldedstructures

• Development and qualification of welding and soldering

additivesaswellasthermalsprayedcoatings

• Chemicalanalyses(sparkemissionspectrometry,carriergas

extractiontodetermineO,N,Hcontentinvariousmetals,

energydispersiveX-rayspectroscopyEDX)

• StructuralanalysisandfeaturedeterminationofFe,Cu,Al

andNi-basedmaterialsbymeansoflightandscanningelec-

tronmicroscopy(SEM)

• Determination ofwelding-related distortion aswell as of

residualstressstatesanddevelopmentofcountermeasures

• Automationofweldingprocessesanddevelopmentofmo-

nitoringsystems

• Externalandconstructionsupervisionwithmobilemeasu-

ringandanalysistechnology

• Designanddimensioningofweldedandsolderedjoints

• Welding technology,

metallurgical and cons-

tructionconsultancy

• Development testing

and inspection of sub-

sea connection techno-

logies

24

T H E R M A L J O I N I N G E N G I N E E R I N G | P R O J E C T S

Theresearchprojectinvestigatestheapplicationofinductiontechnologyforpre-andpost-he-

ating inmanualwetarcwelding.Duetothe influenceof themedia, therearehigh levelsof

hydrogeninputand,duetothestrongconvection,highcoolingratesafterwelding.Asaresult,

criticalmaterialpropertiesandcrackscanresult.Theeffectiveintroductionofenergybymeans

ofinductionisintendedtobeusedforthepracticalcompensationofsubsea-specificrisksduring

wetwelding and consequently, also enabling the safe joiningof high-strength steels. This is

necessaryfortheeconomicalandhigh-qualityrepairofstructuresinhydraulicsteelengineering.

Applicationguidelinesfortheuseofinductionheatingengineeringareindevelopment.

Forfurtherdetailsonthisproject,pleasesee:https://www.igp.fraunhofer.de/en.html

Theweldingprocessingofthick-walledsheets isnecessaryformanyconstructions inthema-

ritimesector inconstrainedpositionsandunderconstructionsiteconditions.ESductwelding

isaweldingprocessforsingle-layerweldingofverticalseamconnectionswhichisparticularly

economicalandwithlowdistortion.However,theinadequatelevelofknowledgeaboutwelding

metallurgyandthelackofsystemtechnologymeanthatitisrarelyused.Theaimistherefore

todevelopamobileESductweldingsystemforuseonbuttandT-joints,aswellastoadaptthe

systemtechnology,weldingengineeringandweldingmetallurgyofESductweldingtoEuropean

manufacturingspecifications.

Forfurtherinformation:https://www.igp.fraunhofer.de/en.html

Insteelconstruction,itisnecessarytoweldattachmentswithoutaprimaryloadbearingfunctionto

structuressubjecttovibrationalstress,whichhasaninfluenceontheservicelifeanddesignofhigh-

strengthsteels.Theprojectinvestigatedwhetherarcbrazingwithcopper-basedsoldersissuitablefor

thesubstitutionofweldingprocessesinsteelconstruction.Theinvestigationsshowthattheuseof

arcbrazingtojoinattachmentscanextendtheservicelifeoftheentireconstructionbyupto500%

withouttheneedforpost-weldtreatment.Forexample,thereisasavingof50tonnesinweightona

tubularsteeltowerforwindturbineswithoutreducingthestaticload-bearingcapacityofthepayload

parts.

Forfurtherdetailsonthisproject,pleasesee:https://www.igp.fraunhofer.de/en.html

INDUCTION HEATING ENGINEERING TO IMPROVE THE WELD SEAM QUALITY FOR SUBSEA WELDING OF FINE GRAIN STEELS

DEVELOPMENT OF A MOBILE ELECTROSLAG (ES) CHANNEL WELDING SYSTEM FOR CONSTRUCTION SITE APPLICATIONS

USE OF ARC BRAZING TO JOIN COMPONENTS ON STEEL STRUCTURES SUBJECT TO HIGH VIBRATION LEVELS

Statically stressed add-on

component

25

NEW MATERIALS AND PROCESSESADHESIVE BONDING TECHNOLOGY

FIBRE COMPOSITE TECHNOLOGY

COATING, WEATHERING AND CORROSION PROTECTION

26

N E W M A T E R I A L S A N D P R O C E S S E S | O V E R V I E W

NEW MATERIALS AND PROCESSES

ThisareaofFraunhoferIGPaddressesbothcurrentjoiningissu-

esoflightweightandcompositeconstructionandthedevelop-

mentandadaptionofproductionmethodsforfibrecomposite

parts.Furthermainresearchfocusesaretheeffectsofageing

onmaterials,adhesivebondedjointsandcoatingsbymeansof

laboratory ageing in an artificial climate. In cooperationwith

theaccreditedtestlaboratoryattheFraunhoferIGP,materials,

jointsandcoatingsystemsaretestedandqualifiedunderstan-

dardisedconditions.Inaddition,newtestingmethodsforspe-

cialapplicationsaredevelopedandemployed.

Inthefieldofadhesivebondingtechnology,therangeofser-

vicesofferedbyFraunhofer IGPextendfromthebonding-op-

timiseddesignofpartsandassemblies, throughtheplanning

anddimensioningofbondedjointsrightuptothedevelopment

andqualificationofthewholebondingprocessandthejoint.

Thefocusinthefieldoffibrecompositetechnologyliesonthe

holisticoptimisationoflargefibrecompositeconstructionssuch

astherotorbladesofwindturbines,shipsuperstructuresand

applicationsincivilengineering.Theworkextendsfromthede-

velopmentofflame-resistantmaterialsthroughproductionen-

gineeringuptothedeterminationandcalculationofindicators.

Inthefieldofcorrosionprotectionandartificialageing,Fraun-

hoferIGP’sfocusinonthedevelopmentandqualificationofin-

novativecorrosionprotectionsystemswithimprovedproperties

andtheidentificationofageinginfluence.

This is new:

Since2020,theindividualdivisionsoftheformerAdhesiveBon-

ding Technology, Fibre Composite Technology and Corrosion

Protectiongrouphaveformedtheirownteams.TheAdhesive

BondingTechnologyteamisheadedbyM.Sc.LindaFröck,while

M.Sc. Stefan Schmidt headsup FibreComposite Technology.

Dr-Ing.MichaelIrmerleadstheCoating,WeatheringandCor-

rosionProtectionteam.Theteamsallcomeundertheumbrella

oftheNewProcessesandMaterialsdepartment,whichisover-

seenbyDr-Ing.NikolaiGlück.

Head of Department

Dr-Ing.NikolaiGlück

Tel.+4938149682-39

nikolai.glueck@igp.fraunhofer.de

ACTIVITIES

• Design and qualification of bonding processes and bon-

dedjointsthroughadhesiveselectionandsurfacepre-tre-

atmentaswellasthedevelopmentofbondingprocesses

• Developmentof automation solutions for adhesive tech-

nologyapplications

• Developmentofcompositemanufacturingprocessesand

structures

• Designanddimensioningoffibrecompositecomponents

• Determination of characteristic values for materials and

compoundsbystaticandcyclictestsandpolymeranalysis

• Analyticalandnumericalcalculationofadhesivejointsand

fibrecompositestructures

• Specificationandqualificationofcorrosionprotectionsys-

tems

• Climatesimulationandacceleratedlaboratoryageingfor

materials,coatings,assembliesandprocesses

• Bondingprocessdevelopmentandcomponenttestsunder

simulatedrealconditionsinaclimatechamber

• Development of test methods for combinedmechanical

andmedialoadsforspecialapplication

27

N E W M A T E R I A L S A N D P R O C E S S E S | P R O J E C T S

Asa resultof increasing lightweightconstruction requirements,adhesive technology isbecoming

moreandmoreimportantasajoiningprocessinshipbuilding.However,alackoflong-termexpe-

rienceinthemaritimesectorstandsinthewayofintegratingadhesivetechnologyintoproduction.

Theaimistofindsuitableinspectionproceduresandintervalsforongoingoperationsandtoexpand

theexperiencewithadhesivejointsinthemaritimesector.Inordertoachievethis,imperfectionsin

adhesivejointstypicalforshipbuildingareanalysedwithregardtotheirdamagepotentialandimpact

onservicelife.Basedonthedataobtained,meaningfulinspectionintervalsaredeterminedfortheuse

ofadhesivejointsinshipbuilding.Inaddition,non-destructive

inspectionmethods(NDT)foruse intheshipyardaswellasatseaarecompiledandcheckedfor

applicability.Forfurtherdetailsonthisproject,pleasesee:https://www.igp.fraunhofer.de/en.html

Inprinciple,theuseofcompositematerialsinshipbuildingisextre-

melypromisingduetothegreatfreedomofdesign,highcorrosi-

onresistanceandconsiderableweightsavings.However,strictfire

protectionregulationspreventtheuseofconventionalfibre-rein-

forcedplasticcomposites(FRP)withorganicmatrices,whichburn

withthereleaseofheatincaseoffire.Thesolutiontothisproblem

istosubstitutetheplasticswithinorganic,non-combustiblematrix

systems.ConventionalmanufacturingprocessesforFRPscannot,

however,beeasilytransferredtotheinorganicmaterials.

TheAnorKompprojectfocusesontheoptimisationandproces-

sing of inorganic systems and processes for the production of

correspondingcompositecomponents.Forfurtherdetailsonthis

project,pleasesee:https://www.igp.fraunhofer.de/en.html

OffshoreWindTurbinesareconstantlyexposedtowind,waterandsalt.Theprotectionofthesteel

structuresisguaranteedbyhigh-performancecoatingsystems.Theapplicationoftheseliquidcoating

materialsisassociatedwithenormouseffortduetoenvironmentalconditionsandqualitymonitoring

inthecoatingprocess.Withthedevelopmentofafoilcoatingsystem,thedemandsontechnicalhall

equipmentcanbereducedconsiderably.Forexample,thereisnoneedforcostlyventilationsystems

orexplosion-proofareas.Thedevelopmentofanautomatedapplicationsystemisinthepipeline.In

combinationwiththefoilcoatingsystem,theneedforqualitymonitoringissignificantlyreduced.

Moreover,feweremployeeswillbeneededtoworkinhazardousareas.

Detailshere:https://www.igp.fraunhofer.de/en.html

INSPECTION METHODS FOR RECURRENT TESTING OF HIGHLY ELASTIC THICK-FILM AND STRUCTURAL BONDS IN SHIPBUILDING APPLICATIONS

NON-COMBUSTIBLE, FIBRE-REINFORCED COMPOSITE COMPONENTS ON COLD-CURING INORGANIC MATRIX SYSTEMS

FOKO-WIND – DEVELOPMENT OF FOIL COATING SYSTEMS AND THEIR APPLICATION TECHNIQUES AS CORROSION PROTECTION FOR OFFSHORE WIND FARMS

28

PRODUCTION ORGANISATION

29

P R O D U C T I O N O R G A N I S A T I O N | O V E R V I E W

PRODUCTION ORGANISATION

Inclosecooperationwithindustrialpartners,theProductionOr-

ganizationteamatFraunhoferIGPdevelopsindividualsolutions

forthedesignoftomorrow’sproduction.

Inthefieldoffactoryandlogisticsplanning,thelatestmethods

andtoolsfromtheDigitalFactory,suchasmaterialflowsimu-

lation, 3D-layout planning and robot simulation, are applied.

Amongotherthings,thissupportsindustrialpartnersinsafegu-

ardingtheirreorganisationorinvestmentprojects.

Atshopfloorlevel,thefocusisondevelopmentandimplemen-

tationofindividualsolutionsforthesmartfactoryinthecontext

ofIndustry4.0.TheseincludeIT-basedproductiondatacapture

systems,whichareusedincombinationwiththemostmodern

positioningtechnologytoincreasethetransparencyofthepro-

ductionprocess.At the same time, it isbecomingevermore

important toensure thatemployeesareprovidedwithdigital

information inafastandflexiblemanner. Inordertoachieve

thesegoals,assistancesystemssuchasdataspectacles,tablets,

andothersmartdevicesareused.

A furtherfieldof focusareergonomicassistancesystems.By

usingintelligentworkplacesystemsandergonomicssimulation,

assemblyprocessescanbedesignedcorrectlyandefficientlyin

termsof ergonomics. In addition, innovativeproduction con-

ceptsbasedonhuman-robotcollaborationaredeveloped.

This is new:

Since2020,HeadofGroupDr-Ing.JanSenderhasalsobeen

head of the Production Systems and Logistics department,

whichunitestheProductionOrganisation,AutomationTechno-

logyandMeasuringofLargeStructuresworkinggroupsunder

oneroof.

ACTIVITIES

Factory Planning and Logistics – Digital Factory

• Productivityandpotentialstudiesforproductionsystems

• Digitalfactorydesignbymeansofmaterialflowandkine-

maticsimulationtosecureinvestmentdecisions

• 3Dlayoutplanninginavirtualrealityenvironmentfornew

planningandreorganisationprojects

• Optimisationofproductionandlogisticssystemsontheba-

sisofleanproductionmethods

Production planning and control - industry 4.0

• Design and implementation of intelligent algorithms for

productionplanningandcontrol

• Developmentof innovative software andhardware solu-

tionsforflexibleproductionmanagement(productioncon-

trolcentre,faultmanagement,etc.)

• Introductionofdigitaltrackandtracingsystemsbasedon

Auto-IDtechnologies(RFID,localisation,etc.)forcomplete

traceabilityoforders

Ergonomics and work design – workers of the future

• Ergonomicanalysisattheworkplace(includingergonomic

simulation)

• Implementationofinnovativeworksystemsbasedonhu-

man-robotcollaboration

• Developmentofergonomicworkplacesystemsandintel-

ligenthandlingsystems

forweightlesshandling

of loads

• Implementationofdigi-

talemployeeassistance

systems for producti-

on, logistics andmain-

tenance

Head of Department

Dr-Ing.JanSender

Telefon+4938149682-55

jan.sender@igp.fraunhofer.de

30

P R O D U C T I O N O R G A N I S A T I O N | P R O J E C T S

In thecourseofdigitisationand the safeguardingofcompetiti-

veness,thereisahighdemandforflexibleautomationsolutions

whichareusedforrepetitiveandstressfulhandlingtasks.Dueto

increasingdemandsonflexibilityforbatchsize1,fullyautomated

robotsystemscannotbeusedeconomically.Here,human-robot

collaborations (‚cobots‘) enable innovative solutions. Intelligent

sensortechnologyeliminatestheneedforsafetyfencesandthis

meansthatadaptive,compactandmobilerobotcellscanbeim-

plemented.Thestrengthsofthehumanbeing(cognitive,motor,

sensoryabilities) are combinedwith thoseof the robot (precisi-

on,highpayloads,longoperatingtimes),sothatemployeesare

de-burdenedandproductivityisincreased.Forfurtherdetailson

thisproject,pleasesee:https://www.igp.fraunhofer.de/en.html

TDespite the enormous importance of

adhering to fixed deadlines in trade

businesses such as interior fitters, the

scheduling is largelyanalogous. Inge-

neral,atpresent,thepotentialofdigiti-

sationisoftennotfullyexploitedinthe

tradesector.Inordertoexploitthefull

optimisationpotentialofthistechnolo-

gy,asystem

forcompletedigitalassemblyplanningwasdevelopedincoope-

rationwithastaircasemanufacturerfromMecklenburg-Western

Pomerania.All relevantdataoriginates

fromdefined interfaces tooverarching

productionsoftwaresystemsandon-si-

tedigitaldatacaptureprocesses.Con-

sistentdatamanagement, system-sup-

ported process structures and the

applicationofrolemodelsallowforan

increase in transparencyof theholistic

planningprocess.

Forfurtherdetailsonthisproject,pleasesee:

https://www.igp.fraunhofer.de/en.html

Particularly intheassemblyofsmallbatchesuptobatchsize1,

attemptsatautomationareoftenuneconomical,sothathumans

areuseddueto theirflexibility.Aimingforasmooth, fault-free

processandageneralreductioninthroughputtimerequiresauxi-

liarysystems.Variousapproachesarebeingpursuedandinafun-

dedprocessinnovation,asystemforvisualsupportaswellasthe

process-dependentprovisionofthecomponentstobeinstalledin

thecontrolpanelhasbeendeveloped.Thisisbasedonthedigital

linkingofthenecessarycomponentsandworkinstructionswith

therespectiveprocesssteps.Theresultsincludeaprojectionforvi-

sualsupportoftheprocess,optimisedmaterialsupplyandholistic

processmapping.Forfurtherdetails,pleasesee:

https://www.igp.fraunhofer.de/en.html

HUMAN-ROBOT COLLABORATION IN MECHANICAL JOINING TECHNOLOGY

DIGITALISATION IN TRADES

AUXILIARY SYSTEMS IN BATCH 1 ASSEMBLY SIZE

31

AUTOMATION ENGINEERING

32

A U T O M A T I O N E N G I N E E R I N G | O V E R V I E W

AUTOMATION ENGINEERING

Automationplaysavitalroleinincreasingthecompetitivenessofa

company,especiallyinthecontextofIndustry4.0.Intheproduc-

tionoflargestructures,inparticular,thechallengeslieinthesmall

batchsizesandthelargeworkpiecedimensionscoupledwiththe

largemanufacturingtolerancesofsemi-finishedproducts.When

using robots in thisenvironment, thecostofprogramming isa

decisivefactorintheuseofrobots.Forthisreason,ourexpertsare

workingonautomaticprogrammingofsuchsystems.Oursolu-

tionsarebeingsuccessfullyimplementedinthemaritimeindustry.

Theirspecialfeatureisthattheyarebasedonanalysisof3Dsensor

dataandrequirenoconnectiontoaCAD/CAMsystem.Inaddition

toprogramming,thehardwarerequirementsfortheuseofrobots

inthemaritimeindustryareoftennotagiven.Therefore,theteam

isengagedinthedevelopmentandrealisationofapplication-spe-

cifichandlingsystemsandend-effectorsforvariousapplications.In

thiscontext,wepursueavarietyofpaths.Ourrangeofsolutions

extendsfromtheclassicrobotcell,throughtheapplicationofcom-

merciallyavailablesystemsinmobilerobotcells,tothecomplete

developmentandimplementationofapplicationandindustry-spe-

cificlargeandheavy-dutyrobotsystems.Theuseofmobilerobot

systems,whichenabletheapplicationofourrobottechnologies

innewindustriessuchasagriculture,isbecomingincreasinglyim-

portant.Weworkcloselywiththespecialistdepartmentsofthe

instituteonaninterdisciplinarybasis.

This is new:

Astate-certifiedtechnicianandmechatronicsengineerwillstrengt-

henthegroupintheprototypicalimplementationofourconcepts.

TheSKMDCAMsoftwareisavailablefortheofflineprogramming

ofourrobotcellforprojectworkintheareaofgenerativewelding

processes.An industrial3Dsurfacescancameraof theCognex

3D-A5000seriesextendsourKUKAKR240testfield.

Group Head

Dipl.-Ing.SteffenDryba

Tel.+4938149682-45

steffen.dryba@igp.fraunhofer.de

ACTIVITIES

Handling technology

• Development and realisation of robots and special kine-

maticsdesignedtocustomerspecifications

• Developmentofapplicationspecificend-effectorsanddevices

Control and regulation technology

• Developmentofindividualrobotandcranecontrols

• Integrationofelectricdrivesystems

• Measuringandsensor technologysolutions for industrial

use

• Processdataprocessingandmachinelearning

Programming / sensor data processing

•Automaticrobotprogramming

•Toolcalibrationandreferencing

•Adaptiverobotcontrol

Robot applications

• Inthefieldofjoining,formingandgenerativeprocesses

• Conceptdevelopmentof robot cells including the safety

concept

• Selectionandintegrationoftoolsandsensortechnology

• Supportforrealisation

33

A U T O M A T I O N E N G I N E E R I N G | P R O J E C T S

HanseaticRohrisacompanythatoffersacomprehensiveservice

forpipingsystemsofallkindswithinthemaritimesector,bothin

newconstruction,attheshipyardorforrepairsduringtheongo-

ingoperationof theship.Thisalso includesfitting replacement

ornewpipelines.Manyofthesepipelinesconsistofadapterpi-

pes,whosecharacteristicfeatureisthat,basedonthepositionof

theflangesinrelationtoeachotherandtheinstallationlocation,

theycanbemanufacturedinbatchsize1accordingtocustomer

specifications.Theproductionoftheseadapterpipesiscurrently

carriedoutinaseriesoftime-consuming,predominantlymanual,

sub-processes.Thisappliesbothtotheactualproduction,aswell

astoupstreamworkstages,suchastheanalysisoftheinstallation

locationandthedraftingofthetechnicaldrawings.Asarule,the

firstsub-stepisthedefinitionofthepipelinegeometry.Thisiscar-

riedoutdirectlyonsite,wherebyallmeasurementsandadditional

photosfordocumentationpurposesarerecorded.Theinstallation

locationisoftendifficulttovieworaccess.Consequently,under

theseconditionsitisoftenonlypossibletomakearoughsketch

byhand,which isthenredrawnandrefinedlateron inthede-

velopmentofficeandwhichalsoservesasthedatabasisfortwo

processesrunninginparallel.Ontheonehand,itisintegratedinto

aCADtoolforqualityassuranceand,ontheother,itisthestarting

pointfortheactualmanufacturingprocess.

Inthemanufacturingprocess,usingthesketchasaguide,thepipe

is firstly disassembled into the necessary individual component

partsandtheindividualpipesegmentspreparedforwelding.At

thispoint,alltheproductionstepsfromcuttingtosizeandseam

preparation toweldingarecarriedoutmanually.The rigidpipe

producedinthiswayisexaminedbyanexpertandcomparedwith

theCADdocumentation.Wherenecessary,adjustmentsorcorrec-

tionsarecarriedout.Therefore,thereisalongprocesschain,but

itisalsoonethatishighlyflexibleandcanbeadaptedtodifferent

pipelinesduetotheveryhighmanualworkcontent.

Theaimofthisinnovationistoimprovetheprocesschaininthe

futurebytargeteduseofselectedtechnicalaidswithoutcompro-

misingtheflexibilityofpipeproduction.

Duetotheuseofapplication-specificsoftwareforrecordingpi-

pelinegeometry,upstreamprocessescanbecombinedandthe

documentationstandardised.With thehelpofamobiledevice,

thesoftwareenablesasketchwithallthenecessaryinformation

tobemadeon site recordingall thenecessarydimensionsand

individualparts.Inaddition,photostakencanbedirectlyassigned

tothepipegeometryanddocumentedbythesoftware.Thedata

suppliedinthiswayisalreadypreparedatthisstagefortheCAD

tool,sothatinfutureitwillnotonlybeaparallelprocessforqua-

litycontrol,butcanalsobedirectlyintegratedintheproduction

processwith thehelpofa script.CADmodelling is carriedout

automaticallyandcanthereforebeuseddirectlytoderiveallthe

production-relevantdata.

Althoughrigidpipesmaybeproduced inverysmallbatchsizes

down to production of unique pieces, the precise definition of

theproductspectrumandfrequentrepetitionoftheprocesssteps

meanthatadegreeofautomationcanbeusefullyapplied.Oneof

theproductionstepsistheweldingoftheroundcomponents.Due

tothesizeofthecomponentsandthemultilayerweldingprocess,

thisstepiscost-intensiveifcarriedoutmanually.Robotsystems,

whicharebecomingincreasinglycheapthesedays,canbeinstal-

ledhereeconomicallyandefficientlysothattheweldingprocesses

selectedfortheprojectcanbeautomatedwiththeuseofrobotics.

Theresultantpartialautomationoftheupstreamweldingproces-

sesandtherobotweldingcellprocesschainsavescustomerstime

andmoney.Beyondthis,theautomaticallygenerateddocumen-

tationbringsthebenefitofconsistentlyincreasedqualityoverthe

longterm.Forfurtherdetailsonthisproject,pleasesee:

https://www.igp.fraunhofer.de/en.html

ADAPTER PIPES AND FLEXI PIPES

MEASURING OF LARGE STRUCTURES

34

35

M E A S U R I N G O F L A R G E S T R U C T U R E S | O V E R V I E W

MEASURING OF LARGE STRUCTURES

ThemainfocusoftheMeasuringofLargeStructuresdevelop-

mentteamisonthecapture,analysisandvisualizationof3D

measuringdata in thefieldofproduction technology.An in-

terdisciplinaryteamandabroadspectrumofdigitalizationme-

thods for stationary andmobile applications are the basis of

innovativesolutionsevenunderdifficultconditions(e.g.under-

water).

Using the latest measurement technology for capturing the

shapeandlocationoflargestructuresprovidesthefoundation

forapplication-specificdevelopmentofanalysisandevaluation

methods of geometric data. Togetherwith industry partners,

theresearchfocusof3Ddata-capturingdevelopsconceptsof

measurement and quality management capturing the actual

buildstateofvariousobjects.Aqualificationofthemeasure-

mentprocessforqualitycontrolaswellasthedevelopmentof

theentireprocesschainofdataacquisitionisperformed,there-

sultsarepresentedaccordinglyandtheinformationisreturned

totheproductionprocess.

Theresearchfielddataanalysisfocusesonsolvingfundamen-

tal questions regarding the interpretation of multidimensio-

nalsensorydata.Theoverallobjectiveiscustomizedsoftware

engineeringfor theautomatedanalysisofhigh-resolution3D

pointcloudsandadditionaldatasources.Withapplication-spe-

cificdevelopmentforautomatedextractionofobject-relevant

informationof2D,3Dorhigherdimensionaldata,modelling

techniquesaredeveloped,measurementandanalysisprocesses

areautomatedandthestateoftheobjectisderived.

This is new:

Wehaveexpandedour competencies and increased theper-

sonnel in thefieldofevaluationandanalysisof sound-based

sensorsystemsforapplicationinmonitoringsystems,producti-

onmonitoringand,inparticular,incombinationwiththeexis-

ting competences in geometric 3Dmeasurement technology

(sensordatafusion).

Group Head

Dr-Ing.MichaelGeist

Telefon+4938149682-48

michael.geist@igp.fraunhofer.de

ACTIVITIES

• Implementationanddevelopmentofmethodsforgeomet-

ricqualitycontrolaswellascontrolofmanufacturingpro-

cessesbyusingmodern3Dmeasuringmethods

• Requirement-specific modelling of high-resolution point

clouddatasets(reverseengineering)

• Analysis, consulting and conceptual design of measure-

ment and testing processes aswell as the derivation of

recommendationsforactiontointegratetheresults

• Implementation of 3D tolerance analyses and measure-

mentcapabilitystudies

• Creationofplanningandsimulationfoundationsbasedon

2Dand3Dmeasurementdataaswellasdatamodelling

foronlineprogrammingofrobots

• Application-specificsoftwaredevelopmentfordataevalua-

tion,analysisandinterpretationofpointclouds

• Developmentofmulti-sensorsystemsforthecaptureand

interpretationof3Ddataandintegrationofadditionalin-

formationsources

• Development of end-to-end systems formonitoring and

interpretationofthecurrentstatusoflargestructures,in-

dividual components, plants and processes (monitoring,

lifecyclemanagement,buildinginformationmodelling)

36

M E A S U R I N G O F L A R G E S T R U C T U R E S | P R O J E C T S

Theageinginfrastructureofmaritimeandinlandwaterwaytrans-

portneedstoberegularlyreviewed.Suchinspectionsarecarried

outbydivingengineerswho inspectthestructuresvisually.Au-

tomatedinspectioncanconsiderablyreducepersonnelandtime

expenditurebyimprovingtheplanningability.Theaimofthisjoint

projectistoachievelargelyautomateddatacaptureprocesses,da-

magedetectionandmodelling.

Forthispurpose,aplatformisbeingdevelopedwithwhichthe

constructionsiteinspectioncanbecarriedoutonthewaterside.

Theplatformisequippedwithahybridmulti-sensorsystemthat

recordsquality-assuredandreproducible3Ddataofharbourstruc-

turesaboveandbelowthewatersurface(seeFigure1).Onthe

basisofthisarea-baseddata,ageometricmodeliscreated,which

isenhancedwithfurtherinformation.Especiallyrelevantarethe

automatic derivation and classification of structural damage by

means of pattern recognitionmethods and the analysis of the

geometricmodelchangesovertime.

Usingthismodel,thestructurecanbeevaluatedandappropriate

measuresinitiated.Theresultswillenabletheportoperatortofo-

cusondeployingaspecificsetofdivingengineersforaconsider-

ablyshorterperiodoftime.Thisservestoincreasebothefficiency

andsafetyatwork.Bycreatingandupdatingthebuildingmo-

dels,theportoperatorcandevisethemaintenanceconceptsand

constructionworkfollowingthebuildinginspectiontransparently

andsafely.Thishasthebenefitofsignificantlyreducingbothport

facilitydowntimesandcost-intensivechangesintheconstruction

process.Completedigitisationoftheconstructiondataprovides

thebasisforsuccessfullifecyclemanagement.

Insummary, theprojectaddresses thedevelopmentof IT-based

hardwareandsoftwaresolutionsforthecombined3Drecording

andmodellingofsurfaceandsub-seastructuresandforthederi-

vationofthedamageclassificationsrequiredforlifecycleenginee-

ring,includingtheplanningofmaintenancemeasures.Duetothe

highdegreeofautomationandassociatedincreaseintheavaila-

bilityofcargohandling,considerablecostandtimesavingscanbe

expectedfortheportoperators.

Formoredetailedinformationonthisproject,pleasesee:

https://www.igp.fraunhofer.de/en.html

3D-HYDROMAPPER – HYBRID 3D INVENTORY DATA CAPTURE & MODEL-BASED TESTING OF WATERWAY STRUCTURES FOR SUSTAINABLE INFRASTRUCTURE LIFECYCLE MANAGEMENT

Water-side over and underwater data capture of a harbour structure by means of a multi-sensor system on a mobile carrier platform.

Diagram: dhp:i

GPS

Intended trajectoryReflector

Surface Scanner

Underwater Scanner

Camera

Tachymeter

Actual trajectory

OWSplus – FLOATING WINDPARKS

37

38

FLOATING WIND PARKS: FRAUNHOFER IGP AS PARTNER IN THE OWSPLUS PROJECT – FLOATING OFFSHORE WIND SOLUTIONS

How entire offshore wind farms can „learn“ to float is

now being researched by 14 alliance partners from in-

dustry and science in Mecklenburg-Western Pomerania.

The OWSplus project, funded by the German Ministry

of Education and Research and the Innovative Regio-

nal Growth Core funding programme, was launched at

Fraunhofer IGP in Rostock at the end of September 2019

as part of an official kick-off event.

Theparticipatingpartnershave set themselvesno lessagoal

thantoreachthenextstageofevolutioninthefieldofregene-

rativepowergeneration.Itisnotpossibletosimplybuildawind

farmeverywhereinthesea.Inadditiontopoliticalinterestsand

environmentalprotectionaspects,oceanographicandgeologi-

calaspectsinfluencedevelopment.Waterdepthsofmorethan

60metresmakeitimpossibletoinstallfixedstructures.Sofar,

therehavebeenahandfulofconceptsforfloatingsubstructu-

res–butthesearenotreadyforindustrialuseand/ornoteco-

nomicallyviable.TheOWSplusprojectaimstocreatestructures

thatenableseriesproductionofthecomponents.

It isnot justwindturbinesthatshouldbemadetofloat.The

transformer station will also be designed to „float“ or even

dive. These transformer platforms take over the transmission

of electrical energy to the mainland. Among other aspects,

theyreduceenergyloss.Inthisway,theyenableenergytobe

transmittedoverlongdistances.Thesystemlimitsaresettobe

increasedfrom900MWto1600MW,evenatgreatdistances

fromthecoast.

Afurther issue isthemaintenanceand installationoftheflo-

ating systems. They are designed to be adapted, also to en-

vironmentswhichdonothavethecorrespondingtechnologyor

maritime infrastructure.Practicablesolutionsforthetransport

and installation of floating offshore technology and suitable

operationandmaintenanceconceptswillalsobecreated.

Fraunhofer IGP working on three sub-projects

TheFraunhofer Institute forLargeStructures inProductionEn-

gineeringIGPisoneoftworesearchinstitutionsparticipatingin

theproject.Inthreesub-projects,thescientistsofFraunhoferIGP

areresearching,amongothertopics,thedevelopmentofvibrati-

on-resistant,insulatedsupportingstructuresforelectricalsystems

andthecorrosionprotectionoffloatingmulti-purposeplatforms.

Thescientistsarealsoworkingonprovidingthemetrologicalun-

derwaterstructureanalysisoffloatingwindfarms.„Wearevery

pleasedtobeabletoparticipateinthismajorproject.Withour

work,weaim tomakeanessential contribution topromoting

thecompetitivenessofoffshorewindpower“explainsDr -Ing.

MichaelIrmer,adding:“Overthenextthreeyears,wewillbeable

todevelopsolutionsthatwillsignificantlyincreasetheavailability

offloatingwindturbinesandtheperformanceoffloatingtrans-

formerplatforms.WithOWSplus,we are taking an important

steptowardsreliableandaffordablerenewableenergy”.

All project partners at the launch event at the end of September

2019. Image: Fraunhofer IGP Rostock

M A J O R P R O J E C T – O W S p l u s

39

ThetotalinvestmentvolumeforOWSplusisapproximatelyEUR

28million.Theprojectissplitintothreecollaborativeprojects:

Jointproject1-Floatingsubstructures;Jointproject2-Floating

multipurpose platforms and Joint project 3 - Installation and

maintenanceoffloatingwindfarms.Theprojectpartnersinclu-

de12companiesandtwoscientificinstitutions.Allthepartners

havemany years of experience in themaritime industry and

especiallyintheoffshoresector.TheOWSplusprojectissetto

runforaninitialtermofthreeyears.

Fraunhofer IGP is working on the following sub-projects

in core growth areas of OWSplus:

Subproject1:

Methods for the simulation-supported planning of various

two-product-matrixmanufacturing plants on the basis of re-

al-timedata.

Subproject2.1:

Developmentofvibration-resistant,insulatedsupportingstruc-

tures for electrical installation

Subproject2.2:

Developmentofatechnologyfortheautomatedcorrosionpro-

The aim of the project is to design floating wind parks. Diagram: OWSplus

tectionoffloatingmulti-purposeplatforms

Sub-project3.1:

Digitaltechnologydevelopmentforequipment-relatedinstalla-

tionmanagement

Subproject3.2:

Sub-seastructuralanalysisoffloatingwindfarms

Project Management

Dr-Ing.MichaelIrmer

Projectmanager

Tel.:+4938149682–222

michael.irmer@igp.fraunhofer.de

www.igp.fraunhofer.de

Formoredetailedinformationintheprojectandsub-projects,

please see:https://bit.ly/3iymSV1or simply scan theQR code

above.

M A J O R P R O J E C T – O W S p l u sIn

no

vati

on

leve

ls

Pro

du

ctPr

oce

ss

Manufacturing

Logistics

Operation

Maintenance

Floating multi-purpose

platform

Installation and operation of

floating wind parksFloating

sub-structures

CAREERS – JOIN US!

40

41

C A R E E R S A T F R A U N H O F E R I G P | J O I N U S !

Human Resources Manager

ClaudiaBäcker

Tel.+4938149682-381

claudia.baecker@igp.fraunhofer.de

Human Resources Manager

MelanieGragert

Tel.+4938149682-221

melanie.gragert@igp.fraunhofer.de

INFORMATION FOR NEWCOMERS AND EXPERIEN-CED PROFESSIONALS

You think living for science and boosting the economy at

the same time is not possible? Well it is! AtFraunhofer,itis

preciselythisparadoxthatisthekeytosuccess.Onlythosewho

breaknewgroundcanshapethefuture.Byturningscientificfin-

dingsintotangibleproductsandservices,youcanmakeasigni-

ficantcontributiontogrowth,competitivenessandemployment

allovertheworld.

You think you can’t do a PhD with a practical orientati-

on? Here, you can!Withus,youwillnotwriteyourdoctoral

thesisalone.Youwillbeintegratedintoourprojectteamsfrom

theverybeginningandwillbeabletoapplyyourknowledgein

practice.AtFraunhofer,youwillfindtheidealmixoftheoryand

practice.

ApositionatFraunhoferIGPismorethanjustajob.Withus,

you benefit from close networkingwith business enterprises

and exchanges with experts beyond your own location.We

are lookingforpersonalitieswhoarecommittedtotheirfield

andwanttohelpshapethefuture.Werelyonyourprofessio-

nalcompetence.Excellentlyequippedoffices,laboratoriesand

workshopsaswellasaculturecharacterisedbyteamspiritcre-

ates thebest conditions for

projectsuccess.

INFORMATION FOR STUDENTS AND SCHOOL PUPILS

You’re looking for more than just a student job! At Fraun-

hofer IGP,youwillhavetheopportunityofgettingatasteof

practicalworkduringyourstudies.Weofferyoua long-term

cooperation and varied activities in different fields. Exciting

tasks indynamicteamsandafriendlyatmosphereawaityou.

Weknowallaboutthechallengeofcombiningstudiesanda

job.That’swhywithus,youcanarrangeyourworkinghours

flexiblyby individualarrangement.Youmayevenfindtheto-

pic for your final dissertation in one of our projects.We are

alwaysopen-mindedandwill tackleany issues togetherwith

you.Cometousasanassistantandwhoknows,maybeyou

willstayonforyourPhD.

Or are you looking for an internship?Dependingonavai-

lable capacity, we offer compulsory internships in accordan-

cewith thestudy regulationsof the respectiveuniversityand

voluntary internships during your studies lasting up to three

monthsaswellasworkexperienceforschoolpupils.

Trainees wanted! We offer our trainees the best possible

start to their professional careers. This includesmore than a

first-classworkingenvironment:practicalworkwithplentyof

freedom.ArmedwiththeFraunhoferknowledgeyouwillhave

acquiredduringyourtraining,youwillfindexcellentopportuni-

ties for a subsequent study

courseorasaqualifiedspe-

cialistopeningup.

W W W . I G P. F R A U N H O F E R . D E / D E / K A R R I E R E

FindoutaboutacareeratFraunhoferIGPinRostockat:

www.igp.fraunhofer.de/de/karriere

Our technical employee Maria Schur at her desk

in the Mechanical Joining Technology Lab. Image:

Fraunhofer IGP Rostock

42

C A R E E R S A T F R A U N H O F E R I G P | J O I N U S !

43

MARIA SCHUR – BREAKING DOWN STEREOTYPES: AN AUTOMOTIVE MECHATRONICS ENGINEER BRINGING THE WINDS OF CHANGE INTO THE LABORATORY

Fraunhofer EMPLOYEE Maria Schur is one of eleven techni-

cal-scientific employees at Fraunhofer IGP in Rostock. She

is still the only woman in her working group – but she is

keen to see more female support in the future.

Maria Schur has beenworking at the Fraunhofer Institute for

LargeStructuresinProductionEngineeringIGPsincetheendof

2018. The 25-year-old fromRostock is a qualified automotive

mechatronicsengineer.Herinterestintechnologyrunsinthefa-

mily.“Myfatherisamastercraftsmaninheating,plumbingand

ventilation.Wehavealwaysdrivenoldcars.Theybrokedownat

times.Myfather repairedthecarshimself. Ialwayswantedto

knowhowthecarworked.Werepairedeverythingtogether–no

matterwhatbrokedownathome”,explainsMaria.Afteranin-

ternshipinacarfactory,herdecisionwasclear:Mariacompleted

hertrainingasacarmechatronicstechnician.„Therewereonly

threewomeninmytrainingyear”,sherecalls.“Mycolleaguesin

thefactorywereveryscepticalatfirstandIhadtoprovetothem

thatIcoulddothesamejobtheyweredoing.Mariaisamember

oftheMechanicalJoiningTechnologydepartmentatFraunhofer

IGP.Sheistheonlywomaninhergroup,butsheisnottheonly

femaletechnical-scientificemployeeattheFraunhoferIGP.

The number of female scientists is growing steadily

Themechatronicsengineer isoneof four technicalemployees

andsevenengineers.Theseelevenemployeesarejoinedbymore

than 60 scientific and technical staff. However, Fraunhofer is

workingonencouragingthenextgenerationofwomeninthe

fieldofmechanicalengineering:“Notcounting thewomen in

admin,wecurrentlyhaveeightfemalestudentsworkingasrese-

archassistants.Wewouldliketoincreasethisnumberandsowe

areaimingtoencouragestudentsfromtheMINTfields(Maths,

IT,NaturalScienceandTechnology)toactivelyapplyforajob

withus”,explainsHumanResourcesManager,ClaudiaBäcker.

A varied range of tasks

“Igetalongverywellwithmycolleagues.Inanycase,working

hereiscompletelydifferenttoworkinginanautomotivework-

shop”,saysMariahappily.Sheisresponsibleforthelaboratory

inthegroup.Herpositionwasnewlycreatedin2018:„Ihada

greatdealtodoatthebeginningtobringorderandanoverview

intothe laboratory.Thework iscertainlyveryvaried. Iprepare

experiments.Ihavetodealwithstandardsandregulationsand

also takeonadministrative tasks. I canandmustundergoon-

going training. For sure, it‘s neverboringhere”.Rostock-born

Mariaappreciatesthegoodcohesionamongcolleaguesaswell

asthefactthatshecanworkfreelyand,aboveall,independent-

ly.InOctober2020,Mariawillstartfurthertrainingtobecome

astate-certifiedtechnician–withsupportfromFraunhoferIGP,

ofcourse.

Women taking their first steps on the career ladder

transform into technical experts

LisaKnaack,HeadofAdministration,beganhercareerattheins-

tituteasanengineerandispleasedabouttheincreasingnumber

offemalescientificstaff:“When IstartedatFraunhofer IGP in

2012,IwasthefirstfemaleresearchassistantattheRostocksite.

Sincethen,thenumberoffemalescientistshassteadilygrown

andyoungwomentakingtheirfirststepsonthecareer ladder

havebecomeexpertswhoare innoway inferiortotheirmale

colleagues”.TheFraunhoferSocietyspecificallysupportsthepro-

motionoffemalescientistswithprogrammessuchas“Talents”

and“speedup”.FraunhoferIGPwillremainactivelyinvolvedin

the future in order to inspire both boys and girls to pursue a

careerinscience.

44

Maximilian Schlicht has been working for Fraunho-

fer IGP since 2019. He started as a scientific research

assistant in 2017 and wrote both his student rese-

arch project and his Master’s thesis at the Institute.

Image: Fraunhofer IGP Rostock

C A R E E R S A T F R A U N H O F E R I G P | J O I N U S !

45

MAXIMILIAN SCHLICHT – OUR SIMULATOR SPECIALIST FOR ANY SITUATION: THE ROAD FROM STUDENT WORK PLACEMENT TO SCIENTIST

Maximilian Schlicht has been working as a scientific rese-

arch assistant at the Fraunhofer IGP since 1 January 2019.

In 2017, he started as a student assistant in the Joining

and Forming by Plastic Deformation department. Max is

a specialist in joining process simulation, which he does

with heart and soul.

“Wearecurrently intheprocessofsimulatingvariousjoining

processes.Thisshowshowwellsimulation,whichisaratherab-

stractconstruct,reallydoesreflectreality”,Maxexplains,sim-

plifyingaverycomplexpartofhiswork.Max,originallyfrom

Schwerin, began his mechanical engineering studies at the

UniversityofRostockin2013.Asastudent,hemadethinking

about his professional future a project. „Back then, a friend

ofminewasalready committed tomechanical engineering. I

found it very interestingand Ipreparedmyportfolioandmy

presentationaccordingly.Myfriendisnowstudyingchemistry

but I‘ve stuckwithmechanicalengineering,which so farhas

proventobetheidealpathforme“,heexplains,smilingashe

doesso.

A part-time job that also helps professional advancement

Whenhewas looking for apart-time job,hebecameaware

of Fraunhofer IGP thanks to a fellow student. “She toldme

aboutherpart-timejobinthefieldofadhesivebondingtech-

nology.Thatwasperfect.IwantedastudentjobwhereIcould

gainworkexperienceduringmystudies.Iappliedtomycurrent

group–atthattimestillmechanicaljoiningtechnology.Andit

workedoutwell”.

Subsequently,Maxalsowrotehisstudentresearchprojectand

hisMaster’s thesis at Fraunhofer IGP.The topicof the thesis:

“Numericalsimulationoftheinstallationprocessofsolidpunch

rivetswithvaryinggeometryandmaterialconcepts”Hewrote

witha fewweeks less time thanoriginallyplanned.Thiswas

because he needed enough time to apply for a research as-

sistantpositionadvertised,whichwastobefilledfrom1Janu-

ary2019.„IdefendedmyMaster’sthesisattheendofNovem-

ber2018,andthenIhadtowritemyapplicationfast“.Hegot

thejob.

What’s going on in the area around joint seams?

MaxhasnotyetdecidedthetopicforhisPhD,butitwilldefi-

nitelybeinthedirectionofsimulation.Atthemoment,Maxis

workingonthe„Friction-basedcrackinitiation“project,which

ispresentedonpage18of this report. „Theadvantageof a

simulation– if you trust it– is thatyougainknowledge that

youcannotmeasure inanyotherway. Inthecurrentproject,

forexample, it isdifficulttoseewhat isgoingon inthearea

aroundthejointseams.Thisiswherewetrytohelpourselves

using simulation, sowe can seewhat happens between the

metalsheetswhentheyarejoined.

Fraunhofer as a link between university and industry

MaxhasnotregrettedhismovefromuniversitydirectlytoFraun-

hoferafterhisstudies.Duringhisstudies,Maxlivedtogetherwith

aphysicistandachemist:threenerdssharingasmallstudentflat!

Bothex-flatmatesandverygoodfriendsarenowalsotakingtheir

PhDs.“But theyhavefar less timethanwedo. It‘smuchmore

comfortablehere. Ihave talkeda lotabout itwith friendswho

wentstraightintoindustry.IthinkthatFraunhoferisdefinitelya

goodspringboard.TheFraunhoferSocietyseesitselfasthetran-

sitionbetweenuniversityandindustry.Youcanmakeavarietyof

differentcontactsinindustryandevenifyoudon‘tcompleteyour

PhDintheend,inmyopinion,Fraunhoferisaverygoodreference

onyourCV.Iamgainingsomuchexperienceinprojectwork”.

Dr Michael Irmer, Team Leader Corrosion Protection,

makes offshore wind turbines more efficient. Image:

Fraunhofer IGP Rostock

46

C A R E E R S A T F R A U N H O F E R I G P | J O I N U S !

47

DR MICHAEL IRMER HAS BEEN AT FRAUNHOFER IGP SINCE 2007 – HE HAS SEEN THE GROWTH OF OUR INSTITUTE!

Born in Rostock, Dr Michael Irmer began his Fraunhofer

career as a student assistant. At that time, the institute was

still an Application Centre (AGP). Today, Dr Irmer is head of

the Corrosion Protection team in the New Materials and

Processes department.

Offshore wind turbines were not his first passion. „Actually, I

wantedtoworkintheautomotiveindustry.Ididaninternshipat

DaimlerinBerlinin2009/2010.Icouldhavewrittenmydiploma

dissertationthere,butmychancesofbeingtakenonwerepoorat

thetime“,explainsDrIrmer.Priortothis,hehadbeenemployed

asaresearchassistantatFraunhoferAGPsinceSeptember2007.

HestudiedindustrialengineeringattheUniversityofRostock,and

inadditiontohis jobasanightporter inahotel,heworkedin

the Application Centre forMechanical Joining Technology. „At

thattime,onlythetechnicalcentreanditsofficeswaslocatedin

thehall“,herecalls.Insteadofwritinghisdiplomadissertationat

Daimler,Michaelcontactedhisoldemployerandendedupwriting

hisdissertationattheAGP inRostock.Histopic:„Development

ofaconceptforthestrategicorientationofaresearchinstitution

inMecklenburg-WesternPomeraniainthefieldofwindenergy“.

ThetransferfromDaimlerworkedoutequallywellhere.

A switch to Adhesive Bonding Technology

On1January2011,MichaeljoinedthestaffofFraunhoferAGP.He

switchedfromMechanical JoiningTechnologytoAdhesiveBon-

dingTechnology.Atthetime,GroupHead,DrNikolaiGlück,had

thePOLARresearchprojectonhisdeskandasked:“Wouldn‘tyou

liketodealwiththesubjectofcorrosion?”Withasmile,Michael

tellsustoday:„Ihadnoideaaboutthat. Ithinktherewasonly

one lecture in the entire course of studies that dealt with corrosi-

on.ButIgladlyacceptedthechallenge.Nikolaiputtheapplicati-

ondocumentsonmydesk,promisedmehissupportandthenit

wasallsystemsgo!”Michaelhascontinuedtoworkwithinthe

areasofcorrosionandoffshorewindenergytothisday.In2019,

hesuccessfullycompletedhisPhDon:“Theimpactofmechanical

stressonthelonger-termeffectivenessofcorrosionprotectionin

multi-layerorganiccoatingsystemsusingtheexampleofoffshore

windturbines”.Corrosionhasamajor impactontheeconomic

efficiencyofoffshorewindturbines.

Corrosion protection will remain an important

subject in the future

Corrosion has amajor influence on the economic efficiency of

offshorewindturbines.“Corrosionisalwaysassociatedwithhigh

costs.Iamahugefanofoffshorewindenergy.Itsimplyhasto

becomeevencheaper.Onestartingpointforthisistoavoidcorro-

siondamageandtomakerepairsascost-effectiveaspossible.The

futurebelongstoenergygenerationwithoffshorewindturbines.

Withtheresultsofmywork,theycanbecomeevenmorecompe-

titive”,explainsMichael.

Plenty of room for development and a great team!

Michael,whoisoriginallyfromRostock,hasneverregrettedthat

hedidnotendupintheautomotiveindustry.„Fromfriendswho

workinthisfield,Iknowthatpeopleworkinanarrowspecialist

area.AtFraunhofer,youcandevelopfarmorefreelyandchoose

thefieldsinwhichyouwork.TheFraunhoferSocietyenablesme

toidentifymystrengthsandtodevelopthem.Thisgivesmethe

chancetoexpandmyskillsonanongoingbasisandtocontinue

mytraininginatargetedmanner”.

Michaelheadsaveryyoungteamandislookingforwardtofuture

tasksat theFraunhofer IGP:“We’reagreat team.We’rehighly

motivatedandupforanychallenge!Wedefinitelywanttogrow

inthefuture”.

Fraunhofer Production Group

TheFraunhoferProductionGroupisaresearchanddevelop-

mentpartnerforthemanufacturingindustry.Morethan2,200

employeesfromeightinstitutesandthreeFraunhoferfacilities

contribute theirknowledgeandexperience.Usingthe latest

findingsfromproductionandengineeringsciencesaswellas

InformationTechnology,theFraunhoferProductionGroupof-

fersarangeofservicesthatcoverstheentireproductlifecycle

orvaluecreationchain.Researchandindustryarecloselylinked

hereonaninterdisciplinarybasis.

www.produktion.fraunhofer.de

Fraunhofer Traffic and Transportation Alliance

SinceMarch2003,anumberofFraunhoferinstitutesandfaci-

litieshavebeenpoolingtheirtransport-relatedexpertiseinthe

FraunhoferTrafficandTransportationAlliance.Themembersof

theAlliancehavesetthemselvesthegoalofdevelopingsuitable

technicalandconceptualsolutionsforpublicsectorandindus-

trialclientsthroughtransport-relevantresearchandtotransla-

ting these solutions into applications. Close, topic-related

cooperationinthetransportsectorenablesthedevelopmentof

holisticsystemandnetworksolutionsforclientsaswellasnew

areasofapplicationthroughthetransferoftechnicalexpertise.

Thisselectionandbundlingofthemostdiversecompetencies

ensuresthatFraunhofercanoffersolutionstailoredtocustomer

needs. www.verkehr.fraunhofer.de

Committee activities

Research Association for Shipbuilding and Marine Tech-

nology e.V.

Prof.Dr-Ing.W.Flügge–MemberTechnicalAdvisoryBoard

Prof.Dr-Ing.habil.K.-M.Henkel–Memberofthetechni-

cal-scientificcommittee

German Welding and Allied Processes Association e.V.

(DVS)

Prof.Dr-Ing.habil.K.-M.Henkel–ChairmanoftheAssocia-

tionforMecklenburg-WesternPomerania;Charimanofthe

CommitteeoftheRegionalAssociations;DeputyPresident

DVSdent

Research Association for Steel Application e.V. (FOSTA)

Prof.Dr-Ing.W.Flügge–MemberoftheTechnicalBoardof

Trustees

Maritime Alliance Baltic Sea Region e.V.

Dr-Ing.J.Sender–Chairman

Cooperation Network RIC MAZA MV e. V.

Dr -Ing. J. Sender – Member of the Board

Technology & Innovation Group for Economy/Science

of Mecklenburg-Western Pomerania

Prof.Dr.-Ing.M.-C.Wanner–Member

Scientific Society for

Assembly Handling Technology Industrial Robots

Prof.Dr.-Ing.M.-C.Wanner–Member

Working Group XXL products

Prof.Dr.-Ing.W.Flügge–Member

German Institute for Structural Engineering

Prof.Dr-Ing.R.Glienke–-Memberoftheexpertcommittee

SVAMetalConstructionandCompositeConstruction

European Research Association for Sheet Metal Proces-

sing e.V.

Dr-Ing.C.Blunk,M.Sc.M.Schwarz–MemberCommunity

CommitteeDVS/EFBAGMF3/V10.3Mechanicaljoining-

Blindrivetsandlockbolts

Dr-Ing.C.Denkert–DeputyChairman/Secretary-Commu-

nityCommitteeDVS/EFBAGMF4/V10.4Mechanicaljoining-

Functionalelements

Dr-Ing.C.Denkert–Member–CommunityCommitteeDVS/

EFBAGMF7/V10.7Mechanicaljoining–DesignandCalcula-

tion

Dipl.-Ing.M.Dörre–Member–CommunityCommitteeDVS/

EFBAGMF4/V10.4Mechanicaljoining–Functionalelements

M.Sc.R.Staschko–Member–CommunityCommitteeDVS/

EFBAGMF1/V10.1Mechanicaljoining–Self-pierceriveting

Prof.Dr-Ing.RalfGlienkeDeputyChairmanCommunityCom-

mitteeDVS/EFBAGMF3/V10.3Mechanicaljoining-blindri-

vetsandlockbolts

ASSOCIATION, ALLIANCE AND COMMITTEE ACTIVITIES

48

ArcWeldingProcessesandProductionSystems

WIND ENERGY NETWORK e.V.

Dr-Ing.NikolaiGlück–Revisorfor2019

Expert opinion activities

German Federation of Industrial Research Associations

“Otto von Guericke” e.V.

Prof.Dr-Ing.W.Flügge,Prof.Dr-Ing.habil.K.-M.Henkel,

Prof.Dr-Ing.M.-Ch.Wanner–ExpertAssessors

Federal Ministry for Economic Affairs and Energy

Prof.Dr-Ing.M.-Ch.Wanner–ExpertAssessorforthe“Inno-

vativeshipbuildingsecurescompetitivejobs”fundinginitiative

German Research Foundation

Prof.Dr-Ing.W.Flügge,Prof.Dr.-Ing.M.-Ch.Wanner–Ex-

pertAssessors

Standardisation activities

German Institute for Standardisation e.V. (DIN)

Prof.Dr.-Ing.R.Glienke–MemberoftheAdvisoryBoardNA

092DINStandardsCommitteeforWeldingandalliedproces-

ses(NAS)

DIN Standards Committee for

Welding and Allied Processes

Dr-Ing.N.Glück–Member-DINWorkingCommitteeNA

092-28AA:Bondingtechnology(DVSAGV8);DINWorking

CommitteeNA092-00-28-01WorkingCommittee:Process

chainbondingtechnology;DINWorkingCommitteeNA092-

00-28-02Work:Bondingoffibrereinforcedplastics;

GfKORR - Society for Corrosion Protection e.V., Wind

Energy Working Group

Dr.-Ing.M.Irmer–Mitglied

Hanse Aerospace e.V., Hamburg

Prof.Dr.-Ing.W.Flügge–MemberoftheScientificAdvisory

Board

REFA Landesverband Mecklenburg-Vorpommern e.V.

Dr.-Ing.J.Sender–MemberoftheBoard

Shipbuilding Association

Prof.Dr.-Ing.M.-Ch.Wanner–HeadoftheFAWorkOrgani-

sationandProductionTechnologyandmemberoftheTechni-

calandScientificAdvisoryBoard

DVS Committee for Technology

Dr-Ing.A.Gericke,M.Sc.O.Brätz–Member-AGV2.5Sub-

seaarcandelectroslagwelding

Prof.Dr-Ing.habil.K.-M.Henkel,M.Sc.O.Brätz,M.Sc.B.

Ripsch-Members-AGV4UnderwaterTechnology

Prof.Dr-Ing.habil.K.-M.Henkel,Dr.-Ing.A.Gericke–Mem-

bers–AGA6.1WeldinginshipbuildingandMarineTechno-

logy–WeldingMethods,ProductionProf.Dr-Ing.habil.

K.-M.Henkel,Dr-Ing.A.Gericke–Members

– AGA6.2Weldinginshipbuildingandmarinetechnology

– Damagetoweldedshipbuildingstructures

Dr-Ing.N.Glück–Member–DVSTechnicalCommittee11

JoiningofPlastics;DVSWorkingGroupAGW4.14Joiningof

endlessfibre-plasticcomposites

Research Association of the DVS

Prof.Dr-Ing.habil.K.-M.Henkel,Dr-Ing.A.GerickeMem-

bers–FA03Arcwelding

Prof.Dr-Ing.habil.K.-M.Henkel,M.SCP.Andreazza,Dr.-Ing.

A.Gericke–Members–FA07Soldering

Prof.Dr-Ing.habil.K.-M.Henkel,M.Sc.O.Brätz,M.Sc.B.

Ripsch–Member–FAV4UnderwaterTechnology

Working Groups of the International Institute of Wel-

ding

M.Sc.O.Brätz–Memeber–IIWCommissionII

ArcWeldingandFillerMetals

Dr.-Ing.A.GerickeMember–IIWCommissionXIIIWorking

Group2Techniquesforimprovingthefatiguestrengthofwel-

dedcomponentsandstructures;IIWCommissionXII

A S S O C I A T I O N , A L L I A N C E A N D C O M M I T T E E A C T I V I T I E S

49

50

PUBLICATIONS 2019

DISSERTATIONS

Denkert,Christian:Bemessung

und Montage umformtech-

nisch ins Blech eingebrachter

Gewindeträger. Universität

Rostock:2019

Irmer,Michael:Einfuss mecha-

nischer Beanspruchung auf

die verbleibende Korrosions-

schutzwirkung von mehr-

schichtigen organischen

Beschichtungssystemen am

Beispiel von Offshore-Winde-

nergieanlagen. Universität

Rostock:2019

FINAL REPORTS

Ambrosat,Tina;Geist,Michael;

Gierschner,Fabian;Knaack,Lisa:

Vorhabensbezeichnung: Ver-

bundprojekt:FINISH – Exakte

und schnelle Geometrieerfas-

sung sowie Datenauswertung

von Schiffsoberflächen für

effiziente Beschichtungspro-

zesse.Hannover:TechnischeIn-

formationsbibliothek

UniversitätsbibliothekHannover

2019

Blumentritt, Benjamin; Flügge,

Wilko;Gatzke,Johannes;Glück,

Nikolai: Entwicklung eines

Verfahrens zum Prozesssiche-

ren Kleben von Halterungen

unter Wasser.In:IGF19.493B

–DVSV4.017–Schlussbericht.

ForschungsvereinigungSchwei-

ßen und verwandte Verfahren

e.V.desDVS.Düsseldorf:2019,

S.1-44

Brätz,Oliver:Optimierung des

Tragverhaltens unter Wasser

gefügter Bolzenschweißver-

bindungen großer Dimensio-

nen für Reparatur- und

Instandhaltungsmaßnahmen.

In: IGF 19.210 B DVS

V4.018-Schlussbericht. For-

schungsvereinigung Schweißen

und verwandte Verfahren e.V.

des DVS. Düsseldorf: 2019, S.

1-108

Ebert, Andreas; Glienke, Ralf:

Execution and reliability of

slip-resistant connections for

steel structures using CS and

SS.In:RFCS-ProjectFinalReport,

Grant Agreement RFSR-CT-

2014-00024.2019

Eggert,Martin:Schlussbericht

zum Projekt: OWSMV –

Offshore Wind Solution

Mecklenburg-Vorpommern.

2019

Fischer, Anne: Schiffbauliche

Unikatproduktion mit Erwei-

terter Realität (SUPER). 2019

Fuchs,Normen;Nehls,Thomas;

Nowak,Karina;Schlicht,Maximi-

lian:Fügen von Strukturbau-

teilen aus hochfesten

Aluminiumknetlegierungen

durch Vollstanznieten aus

höchstfesten Aluminiumle-

gierungen (Aluminium- Voll-

stanznieten). In: wvmetalle.

WirtschaftsVereinigungMetalle.

2019

Holleitner, Felix;Kappis, Lukas:

Charakterisierung des Einflus-

ses mechanischer Fügeverbin-

dungen auf das Dämpf-

ungsverhalten zusammenge-

setzter stahlbaulicher Trag-

werkstrukturen. In: EFB-

ForschungsberichtNr.519. EFB

Europäische Forschungsgesell-

schaftfürBlechverarbeitunge.V.

Hannover:2019,S.1-158

Schmidt, Stefan: Tragfähig-

keitserhöhung von geklebten

FKV- und Multi-Material-Ver-

bindungen durch optimierte

Gestaltung und Fertigung der

FKV- Fügeteilwerkstoffe. In:

IGF 19.212 BR-DVS 11.060 –

Schlussbericht.Forschungsverei-

nigung Schweißen und

verwandte Verfahren e.V. des

DVS.Hannover:2019,S.1-175

Staschko, Robert: Modellie-

rungsstrategie zur anwen-

dungsgerechten Simulation

stanzender Fügeverfahren

bei FVK- Hybridstrukturen.In:

EFB-ForschungsberichtNr.515.

EFBEuropäischeForschungsge-

sellschaft fürBlechverarbeitung

e.V.2019,S.1-132

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THOLOGIES

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tallurgische Untersuchung

des Elektroschlacke-Kanal-

schweißens zur Qualifizierung

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Haberecht,Tobias;Wanner,Mar-

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Brätz,Oliver:Artgleiches Un-

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Brätz, Oliver: Induktion als

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Brätz, Oliver: Schweißen von

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Brätz,Oliver;Haas,Fabian;Hau-

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mung und Wärmebehand-

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chen 2019

Dörre, Maik; Ebert, Andreas;

Henkel, Knuth- Michael (Uni

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29th International Ocean and

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Dörre, Maik: Einsatz von

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Fröck,Linda:Development of a

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toSyntheticMaterials.Dresden

2019

Fröck, Linda: Nachbearbei-

tungsfreies Halterkleben auf

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tungen. WAB-Arbeitskreissit-

zungKlebverbindungen.2019

Fröck, Linda: Unterwasser-

kleben – Entwicklung eines

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ren Kleben von Halterungen

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Gatzke, Johannes: Unterwas-

serkleben – Entwicklung ei-

nes Verfahrens zum prozess-

sicheren Kleben von Halte-

rungen unter Wasser. 10.Kle-

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Gericke, Andreas: Impro-

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BrazingandDiffusionBonding.

Aachen 2019

Gerke,Thomas:Increasing the

load- bearing capacity of slip

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use of structural adhesives

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CongrèsFrançaisdeMécanique.

Brest,Frankreich2019

Glienke, Ralf: Experimentelle

Untersuchung zur Schwing-

festigkeit an hochfesten

Schrauben großer Durchmes-

ser.3. FachtagungSchrauben-

verbindung 2019 – Große

Schraubenverbindungen>M20

imFokus.Meschede,2019

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ner integralen Leichtbaudeck-

sektion aus Composite

werkstoffen für Binnenfahr-

gastschiffe.MariLight-Auftakt-

veranstaltung 2019. Bremen

2019

Glück,Nikolai:Prozesssicheres

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terwassertechnik-Tagung 2019.

Hamburg2019

Haberecht,Tobias:Entwicklung

einer ortsveränderlichen Ro-

boterzelle zum Zerlegen von

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roboter.2019

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Erschließung neuer Anwen-

dungsfelder. Arbeitsgruppe

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München.München,2019

Hauer,Michel:Herstellung ka-

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chael;Ripsch,Benjamin:Use of

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Machine Learning Algorith-

men zur Prädiktion vakanter

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am Beispiel der Produktion

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Illgen,Benjamin:Simulation ba-

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construction for large

offshore structures. 52ndCIRP

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Irmer,Michael:OWEA Coating

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tion performance after com-

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EUROCORR2019,SevillaSpain.

Sevilla,Spanien

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sionsschutzwirkung von

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Ulm2019

Irmer,Michael:Väterchen Rost

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Jagusch, Konrad: Digitalisie-

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fen. MAZA Mitgliederver-

sammlung.2019

Jagusch,Konrad:Transparency

in the design-accompanying

production on shipyards.

52ndCIRPConferenceonManu-

facturing Systems. Ljubljana

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Junkers, Patrick (HYTORC/Bar-

barino&KlipGmbH):Kosten-

einsparung und Qualitäts-

steigerung in der Windener-

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tim2019.Rostock,2019

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tal studies on the clamp

length diameter ratio in

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CongrèsFrançaisdeMécanique.

Brest,Frankreich2019

Kalkowsky, Florian: Extension

of the application limits of

blind fasteners for joining

high-strength steels in metal

lightweight constructions.

CongrèsFrançaisdeMécanique.

Brest,Frankreich2019

Klink,Steffen;Sender,Jan:Me-

thod for integrated logistics

planning in shipbuilding. 13th

CIRP Conference on Intelli-

gent Computation in Manu-

facturing Engineering.Gulfof

Naples,Italy2019

Klötzer,Christian:Neue Ferti-

gungstechnologien in der

maritimen Produktion.8.Zu-

kunftskonferenzWindundMari-

tim.Rostock2019

Lauer,Sascha:Mechanisierung

eines Mehrlagenschweißpro-

zesses zum Fügen von

Offshore- Rohrverbindun-

gen. 8. Zukunftskonferenz:

Wind&Maritim.Rostock2019

Niemeyer,Frank:Untersuchung

zur Messgenauigkeit von La-

serscannern unter Wasser am

Beispiel des Sea Vision 3D-La-

sersystems. BeiträgederOlden-

burger3D-Tage2019.Oldenburg

2019

Ripsch, Benjamin: Kostenein-

sparung und Qualitätssteige-

rung in der Windkraft durch

wartungsarme Schraubver-

bindungen.Zukunftskonferenz

Wind&Maritim.Rostock2019

Ripsch, Benjamin: Vorspann-

krafterhaltende Sicherung

unter Wasser montierter

Schraubverbindungen. 9.

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technologie.München2019

Schmidt,Stefan:OptiBondFKV-

Tragfähigkeitserhöhung von

geklebten FKV- und Multi-

Material-Verbindungen

durch optimierte Gestaltung

und Fertigung der FKV- Füge-

teilwerkstoffe.DVSW4Plen-

arsit zung „Fügen von

Kunststoffen“.Würzburg2019

Schmidt, Stefan: Tragfähig-

keitserhöhung von geklebten

FKV- und Multi-Material-Ver-

bindungen durch optimierte

Gestaltung und Fertigung der

FKV-Fügeteilwerkstoffe (Op-

tiBondFKV). 19. Kolloquium

Gemeinsame Forschung in der

Klebetechnik,Köln.Köln,2019

Wurst, Oliver: Ortsveränder-

liche Roboterzellen zum Zer-

legen von Rotorblättern. 8.

Zukunftskonferenz Wind und

Maritim.Rostock2019

P U B L I C A T I O N S 2 0 1 9

56

CONTACTS

ORGANISATION

Director l Chair in Manufacturing Technology

Prof.Dr-Ing.WilkoFlügge

Tel.:+4938149682-20

wilko.fluegge@igp.fraunhofer.de

Deputy Director l Chair in Joining Technology

Prof.Dr-Ing.habil.Knuth-MichaelHenkel

Tel.:+4938149682-30

knuth.henkel@igp.fraunhofer.de

Institute Assistant

Dipl.-Ing.SabineWegener

Tel.:+4938149682-13

sabine.wegener@igp.fraunhofer.de

Institute Assistant

VirginieRogge

Tel.:+4938149682-11

virginie.rogge@igp.fraunhofer.de

Head of Administration

M.Eng.LisaKnaack

Tel.:+4938149682-226

birgit.latzko@igp.fraunhofer.de

Head of IT

Dipl.-Wirt.-Inf.MarcusBaier

Tel.:+4938149682-57

marcus.baier@igp.fraunhofer.de

Public Relations

M.A.SilkeSchulz

Tel.:+4938149682-224

silke.schulz@igp.fraunhofer.de

COMPETENCES

Joining and Forming by Plastic Deformation

M.Sc.PascalFroitzheim

Tel.:+4938149682-228

pascal.froitzheim@igp.fraunhofer.de

Mechanical Joining Technology

Dipl.-Ing.MaikDörre

Tel.:+4938149682-239

maik.doerre@igp.fraunhofer.de

Thermal Joining Engineering

Dr-Ing.AndreasGericke

Tel.:+4938149682-37

andreas.gericke@igp.fraunhofer.de

New Materials and Processes

Dr-Ing.NikolaiGlück

Tel.:+4938149682-39

nikolai.glueck@igp.fraunhofer.de

Adhesive Bonding Technology

M.Sc.LindaFröck

Tel.:+4938149682-140

lina.froeck@igp.fraunhofer.de

Fibre composite Technology

M.Sc.StefanSchmidt

Tel.:+4938149682-223

stefan.schmidt@igp.fraunhofer.de

Corrosion Protection

Dr-Ing.MichaelIrmer

Tel.:+4938149682-222

michael.irmer@igp.fraunhofer.de

57

Production Systems and Logistics

Production Organisation

Dr-Ing.JanSender

Tel.:+4938149682-55

jan.sender@igp.fraunhofer.de

Automation Engineering

Dipl.-Ing.SteffenDryba

Tel.:+4938149682-45

steffen.dryba@igp.fraunhofer.de

Measuring of Large Structures

Dr-Ing.MichaelGeist

Tel.:+4938149682-48

michael.geist@igp.fraunhofer.de

AUXILIARY SUPPORT

Head of Testing, Monitoring and Certification

Prof.Dr-Ing.RalfGlienke

Tel.:+4938149682-40

ralf.glienke@igp.fraunhofer.de

Head of Test Laboratory

M.Sc.HolgerBrauns

Tel.:+4938149682-220

holger.brauns@igp.fraunhofer.de

Head of Technical Services

Dipl.-Ing.KayMüller

Tel.:+4938149682-60

kay.mueller@igp.fraunhofer.de

University Chair Contact

Dr-Ing.UlrichKothe

Tel.:+4938149682-50

ulrich.kothe@igp.fraunhofer.de

CONTACTS BY SECTOR

Shipbuilding

Dr-Ing.JanSender

Tel.:+4938149682-55

jan.sender@igp.fraunhofer.de

Aircraft Construction

M.Sc.ThomasNehls

Tel.:+4938149682-65

thomas.nehls@igp.fraunhofer.de

Metal Alloy and Steel Construction

M.Sc.MaikDörre

Tel.:+4938149682-239

maik.doerre@igp.fraunhofer.de

Mechanical Engineering

Dipl.-Ing.SteffenDryba

Tel.:+4938149682-45

steffen.dryba@igp.fraunhofer.de

Wind Energy Turbines

Dr-Ing.NikolaiGlück

Tel.:+4938149682-39

nikolai.glueck@igp.fraunhofer.de

Rolling Stock and Automotive Manufacturing

Dr-Ing.ChristianDenkert

Tel.:+4938149682-64

christian.denkert@igp.fraunhofer.de

Maritime Technology

Prof.Dr-Ing.habil.Knuth-MichaelHenkel

Tel.:+4938149682-30

knuth.henkel@igp.fraunhofer.de

58

SOURCES/IMPRINT

Publisher

FraunhoferInstituteforLargeStructuresin

ProductionEngineeringIGP

Prof.Dr.-Ing.WilkoFlügge

Albert-Einstein-Straße30

18059Rostock

Germany

Tel.:+4938149682-0

Fax+4938149682-12

info@igp.fraunhofer.dewww.igp.fraunhofer.de

Editorial, layout and production: Mag.SilkeSchulz

Image credits: Excludingall Fraunhofer IGP images:Gesell-

schaft für Wirtschafts- und Technologieförderung Rostock

mbH,RostockBusinessandTechnologyDevelopmentGmbH:

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haveinsomecasesrefrainedfromusingbothfemaleandmale

languageformsinourwording.However,thisdoesnotimply

anydiscriminationagainstthefemalesex,butshouldbeunder-

stoodasgender-neutralinthesenseoflinguisticsimplification.

Reportingperiod:1Januaryto31December2019

Allrightsreserved.

Reproductionanddistributiononlywithpermission

oftheeditorialoffice.

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