Lightweight construction is a globally significant research field, in which Germany has assumed a lead role. Fibre composites find increasing application, particularly in automotive,  offering not only a low density but the possibility of integrated functions. Over the past few years the Fraunhofer ICT in Pfinztal has carried out extensive process and material research and development work for the lightweight sector.

The  main focus of research at the Fraunhofer Project Centre for Composites Research Western will therefore be fibre composites for lightweight construction in various markets. Work will be oriented particularly towards the regional North American market.

The Fraunhofer Project Centre will be equipped with a latest state of the art hydraulic press with a maximum clamping force of 2,500 tons suitable for research on parts in full industrial scale. Material and process research will be carried out in the technologies Direct – Sheet Moulding Compound (D-SMC), Long Fiber Reinforced Thermoplastics (LFT) and High Pressure Resin Transfer Moulding (HP RTM) for a sustainable use of the lightweight potential of these high volume composite technologies in the automotive industry, machines and equipment industry and aviation industry.

Equipped with this full industrial scale processing equipment and as a part of The University of Western Ontario the Fraunhofer Project Centre offers possibilities for collaboration in bilateral projects up to multilateral public funded research projects. The service portfolio of the FPC contains:

• Research in materials, simulation, design
•  Optimising of existing processes and materials
•  Development of new processes and materials as well as transition of lab scale basic research results into industrial applications
• Part, process, material and tooling innovations
• Competence along the whole value chain from product engineering to demonstrator part manufacture

Western contributes its scientific excellence in the field of surface technologies and material sciences. The clear strategic orientation of the University towards modern manufacturing systems is also a key aspect within the cooperation. 

Additionally, London is located at the heart of the Canadian automobile industry, and only a short distance from the major North American automotive construction centres in Detroit. The University has obtained significant funding from the City of London for cooperation within the Fraunhofer Project Centre. The joint Project Centre will run for an initial period of five years.

PRECISION TEMPERATURE CONTROL AT POUR
Tecnalia, which has worked on technology to produce vitreous steel then devitrify it to obtain nano-structures that enhance the final mechanical properties of the product, haS now made use of a High-Powered Thermal Plasma torch, enabling heating precision quantity of metals at the required temperature and at the precise moment of casting, when molten metal (left) has to be poured from the furnace or ladle.

Precision is fundamental. Overheated metal oxidises easily and can lose characteristics to the point of invalidating it for the production of parts.

The “plasma torch” enables programming the range of temperature at which it is desired to cast the metal and maintain this automatically over the whole period of the casting process.

Besides, the exclusive characteristic that the plasma provides, this operation can be undertaken using an external heating element, separate from the furnace itself, facilitating maintenance tasks and reducing general casting costs.

The success of the system was quickly evident thanks to marketing efforts of SERT Metal, which has been licensed to commercially exploit the patent. The Bizkaia-based blast furnace company Fuchosa and the Valladolid-based Lingotes Especiales  already have the equipment installed and vouch for its high performance.