Projects
Ongoing Projects
NATUR – Sustainable Lightweight Structures with Thermoset Materials for Environmentally Friendly Aviation
Aviation Research and Technology Program (LuFo VI-3)
Funding agency: German Federal Ministry for Economic Affairs and Climate Action BMWK (Grant number: 20W2207D)
Project management organization: DLR e.V. – Aviation Research
Project partners: Airbus Aerostructures GmbH, Airbus Operations GmbH, Premium Aerotec, Ostseestaal GmbH & Co. KG, Fraunhofer Institute IGCV, Fraunhofer Institute ICT, Fraunhofer Institute IFAM
Project duration: 10.2023 – 12.2026
Within the framework of this research project, innovative joining technologies for hybrid lightweight structures in aviation are being investigated. The focus is on the development and evaluation of cohesive (material-bonded) joints between different material systems in order to enable robust, high-performance, and resource-efficient structures. Initially, hybrid joints are manufactured and tested on specimen level. A systematic screening approach is used to identify key process parameters and to analyze their influence on joint quality. Based on these findings, selected process parameters are optimized to further improve joining performance according to defined target criteria. Subsequently, the technology is gradually transferred from laboratory-scale specimens to component-like structures. A key application case is an aviation-relevant structural component: a window frame that is intended to be cohesively joined to the aircraft fuselage using ultrasonic welding. During the scaling process, critical structural details are investigated in particular, before implementation on a realistic geometry and comprehensive structural testing are carried out.
The project therefore provides important contributions to process design, evaluation of joint zone properties, and the transferability of advanced joining technologies to complex aircraft structures.
PhD Student
Polymer Composites Technology
- Phone: +49 821 598 69204
Email: fabian.miller@uni-auni-a.de ()
FORinFPRO – Intelligent Manufacturing Processes & Closed-Loop Production
Funding program: “High Technologies for the 21st Century”
Funding agency: Bavarian Research Foundation (Bayerische Forschungsstiftung) (Grant number: AZ-1596-23)
Project partners: Five chairs of the University of Augsburg, as well as various research institutions and industrial partners
Project duration: 03/2024 – 02/2027
The project systematically investigates a dynamic ultrasonic welding process for hybrid lightweight structures in order to establish the basis for robust process execution and future automated closed-loop control. Relevant process influences such as welding parameters, robot-specific effects, component-related factors, and external conditions (e.g., climate) are recorded, evaluated, and reduced to the most significant parameters.?Based on the collected process data, a parameterizable mathematical model is developed, which serves as the foundation for deriving and implementing a process control strategy. For validation, experimental studies are carried out on coupon level. Specimens with intentionally introduced geometric deviations (e.g., thickness transitions) are used to simulate realistic manufacturing influences and potential defects. The generated datasets are then used to evaluate and optimize the developed controller.?
As an exemplary application case, an Erlangen beam is investigated. Its outer shell is manufactured from recycled thermoplastic CFRP material, while the internal structure is produced from injection-molded thermoplastic. This assembly is subsequently joined to a thermoset base plate using ultrasonic welding. In this way, both material-related and process-related challenges of hybrid material combinations are addressed.
PhD Student
Polymer Composites Technology
- Phone: +49 821 598 69204
Email: s.alantor@uni-auni-a.de ()
Completed Projects
HyBDTT – Development and Manufacturing of a Hybrid Thermoset/Thermoplastic CFRP Tank Structure for Microlaunchers
Bavarian Space Research Program (RaFo-Bayern)
Funding agency: Bavarian State Ministry for Economic Affairs, Regional Development and Energy STMWI (Grant number: MRF-2107-0026)
Project management organization: IABG
Project partners: DLR e.V. – ZLP; RFA – Rocket Factory Augsburg AG
Project duration: 01/2022 – 06/2025
This research project focuses on the development and manufacturing of a hybrid tank structure for microlaunchers. The chair’s main focus lies in the characterization of these hybrid tank structures. The project aims to advance the development and implementation of a material-bonded fiber-reinforced tank structure composed of different matrix systems for a microlauncher.
The development is carried out with an emphasis on potential industrial application, using primarily fiber-reinforced thermoplastics and fiber-reinforced thermosets. This combination is intended to exploit the material-specific advantages in terms of lightweight construction, manufacturability, and resource efficiency
PhD Student
Polymer Composites Technology
- Phone: +49 821 598-69203
Email: niklas.chaloupka@mrm.uni-augsburgmrm.uni-augsburg.de ()