CLUSTER OF EXCELLENCE MERGEMerge Technologies for Multifunctional Lightweight StructuresEXC 1075

www.tu-chemnitz.de/MERGE

CLUSTER OF EXCELLENCE MERGEMerge Technologies for Multifunctional Lightweight StructuresEXC 1075

www.tu-chemnitz.de/MERGE

1. What/who is MERGE2. Main fields of activities of MERGE 3. Internationalisation of the cluster 4. Fields of interest for European co-operations

CLUSTER OF EXCELLENCE MERGEMerge Technologies for Multifunctional Lightweight Structures

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MERGE works together with:

› 25 Principal Investigators and 13 Participating Researchers› Participating Institutes:

› 14 Institutes of TUC› 3 Institutes of DUT› 7 Faculties› 2 Affiliated Institutes of TUC › 2 Fraunhofer Institutes› 1 Leibniz Institute

CLUSTER OF EXCELLENCE MERGEMerge Technologies for Multifunctional Lightweight Structures

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Partners in Science and Industry

Presently, further more than 300 companies ( 250 SMEs) in research and innovation projects involved

CLUSTER OF EXCELLENCE MERGEMerge Technologies for Multifunctional Lightweight Structures

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General Problems› increasing prices of energy andraw materials

› climate change by greenhouse effect, global warming

Requirements› energy savings› mass reduction

Approach› Merge Technologies› Lightweight Structures

Strategy› Bivalent Resource Efficiency

Mission

CLUSTER OF EXCELLENCE MERGEMerge Technologies for Multifunctional Lightweight Structures

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In-line and In-situ Process Chains

CLUSTER OF EXCELLENCE MERGEMerge Technologies for Multifunctional Lightweight Structures

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Interacting Research Domains

CLUSTER OF EXCELLENCE MERGEMerge Technologies for Multifunctional Lightweight Structures

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Main objectives of IRD ASupply of intelligent, high-functional, hybrid semi-finished products and their implementationin in-line processes

› Fusion of textile and foil technology› Roll-to-roll functionalisation› Multi-axial multiply prepregs (MMP)› Large-scale and continuous manufacture

IRD A: Semi-finished Products and Preform Technologies

CLUSTER OF EXCELLENCE MERGEMerge Technologies for Multifunctional Lightweight Structures

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Main objectives of IRD BFunctional enhancement of metal-intensive technologies for manufacturing of hybrid metal/plastics composites

› Graded metal structures› High pressure forming with polymer melts› Shape memory alloys in textiles

IRD B: Metal-intensive Technologies

CLUSTER OF EXCELLENCE MERGEMerge Technologies for Multifunctional Lightweight Structures

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Basic components for multi-functional lightweight strucutres

IRD C: Textile-/Plastic-based Technologies

Main objectives of IRD CIn-situ plastics-based integration of adaptedtextiles, metals and micro-/nanosystemsintegration offers crucial advantages regarding:

› Material and energy efficiency› Freedom of design› Mass production

CLUSTER OF EXCELLENCE MERGEMerge Technologies for Multifunctional Lightweight Structures

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IRD D: Micro- and Nanosystems Integration

Main objectives of IRD DMicro- and nanosystems in hybrid structures by integration of:

› Sensors, actuators› Electronics› Power supply› Communication interfaces

CLUSTER OF EXCELLENCE MERGEMerge Technologies for Multifunctional Lightweight Structures

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IRD E: Interface optimization and design

Main objectives of IRD EInterface design according to requirements

› Investigation of surface properties› Development and application of adhesion promoters› Composite behaviour under fracture conditions› Fatigue properties and improvement

CLUSTER OF EXCELLENCE MERGEMerge Technologies for Multifunctional Lightweight Structures

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IRD F: Modelling, Integrative Simulation and Optimisation

Main objectives of IRD FModelling, simulation and optimisation of hybrid structures and their production processes

› Advanced constitutive laws and experimentalcharacterisations

› Coupled simulations, bivalent optimisation› Adaptive high-precision FEM› Efficient data management and computing

CLUSTER OF EXCELLENCE MERGEMerge Technologies for Multifunctional Lightweight Structures

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Infrastructure of MERGE

CLUSTER OF EXCELLENCE MERGEMerge Technologies for Multifunctional Lightweight Structures

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New MERGE Technology Centre (MTC)

Research Hall (1st Construction phase)

› Costs: 12,6 Mio. EUR› Area: 3.565 m²› Construction: 05/2014 – 09/2015

MERGE Machine

› Integrative Lightweight ManufacturingComplex (ILCx)

› Dimensions: 25 metres in length, 10 metres in width and 8 metres in height

› Weight: about 200 tonnes

© Ludes Generalplaner GmbH

CLUSTER OF EXCELLENCE MERGEMerge Technologies for Multifunctional Lightweight Structures

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• Corrosion athybridsolutions

• Mechanicalprocessingoffibre-reinforcedcompositesandhybrid solutions

• Productionprocessofthermoplastic composites

• Lightweightsolutionswithwires

• Hydrauliccylinderaslightweightsolution

• ImprovementofCFL-filamentwounding

• Fire-/heatresistantlargescalecomposites

• Textile reinforcedcellularplasticsandcomposites

• Manufacturingandprocessingofhybridtextile reinforced composites

• Ceramic-matrixcomposites

• In-lineproductionofhigh-strengthandhigh-stiffnesshybridlaminatesbasedonthermoplastics

Possible co-operation topics composites and hybrid solutions

CLUSTER OF EXCELLENCE MERGEMerge Technologies for Multifunctional Lightweight Structures

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Possible co-operation topics Additive Manufacturing

Post Treatment Processes

Heat Treatment

Additive Manufacturing

Sensorintegrationin complexAM-parts

DevelopmentofHybridcomponents

Newmaterial processing

Development ofhybridprocessparameters(latticestructures)PerformanceParameterfor SLM-Processing(Increasingproductionrate)OptimizationofAdditiveManufacturingDesign RulesCFD-Simulations fordefinedPostTreatmentProcesses

…

CLUSTER OF EXCELLENCE MERGEMerge Technologies for Multifunctional Lightweight Structures

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MERGEuropeLightweight innovation network

CLUSTER OF EXCELLENCE MERGEMerge Technologies for Multifunctional Lightweight Structures

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Composites Centre SwedenEUROPEAN LIGHTWEIGHTING CLUSTERS ALLIANCE – ELCA

SUBMITTED HORIZON 2020-INNOSUP 2016-2017)

National Composites Centre

Lulea, Sweden

LIGHTerSweden

Open Hybrid Lab FactoryWolfsburg, Germany

MERGEChemnitz, Germany

AZLAachen, Germany

ARENA 2036Stuttgart, Germany

MAI CarbonAugsburg, Germany

Bristol, UK

IRT Jules VerneNantes, France

AESICOMValencia, Spain

IMASTNaples, Italy

CLUSTER OF EXCELLENCE MERGEMerge Technologies for Multifunctional Lightweight Structures

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Thank you for your attention ! We are looking forward to co-operating with you.

Speaker Jonas Stiller jonas.stiller@mb.tu-chemnitz.de

Prof. Dr.-Ing. Daisy Nestlerdaisy.nestler@mb.tu-chemnitz.de

MERGE COO Dr.-Ing. Jürgen Tröltzschjuergen.troeltzsch@mb.tu-chemnitz.de

MERGE EU-project coordination Dr. Katharina Schöps

katharina.schoeps@mb.tu-chemnitz.de