annual report 2008 · coated ball valves in 2008 the results of a joint research project with the...

Internet: www.iws.fraunhofer.de

Annual Report 2008

Annual Report2008

Fraunhofer IWS Annual Report 2008 1

Early 2008 demonstrated still booming industry conditions butended with a downward economic trend. This negative devel-opment in the overall economy affects research and develop-ment spending with a certain delay. Therefore in spite of theconditions, the IWS was able to repeat the excellent result ofthe previous year. Research revenues from industrial customerscame close to 8 million Euros. In 2008 we expanded our ca -pacities and hired ten additional employees.

Our project center CCL in the USA finished 2008 equally well.In particular the laser beam welding of batteries for future cargenerations contributed to the success. Our project group atthe DOC was active in the area of energy technologies; the scientists successfully developed new coatings and coating systems for fuel cells.

An IWS highlight was the development of an extremely wearresistant coating, which drastically reduces the coefficient offriction even when using lubricants. This IWS coating will haveautomotive powertrain applications to reduce CO2 emissionand fuel consumption of cars.

In 2008 several innovative laser technologies were developedas well as commercialized.

A special event represented the signing of a cooperation agree-ment with the Technical University in Wrocław at which federalchancellor Angela Merkel participated. The establishment ofthe project center aims at improving the research cooperationwith Poland, at exploiting the synergies of complementaryexpertise, and especially at developing the Eastern Europeanmarkets.

For 2009 we expect a decline in industrial revenues. However,based on already issued grant agreements, we anticipate anincrease in publicly funded projects; so we face the difficultyear with moderate optimism.

Preface


The secret of success is determination.Benjamin Disraeli

Eckhard Beyer

Fraunhofer-Institut für Werkstoff- und Strahltechnik IWS

Fraunhofer Institute forMaterial and Beam Technology IWS

Winterbergstraße 28 01277 Dresden Germany

phone: +49 (0) 351 2583 324 fax: +49 (0) 351 2583 300

e-mail: [email protected] website: www.iws.fraunhofer.de

Fraunhofer IWS Annual Report 20084

Contents

Preface 3

Contents 5

Highlights of 2008 6

Institute profile 8

Overview 8

Institute equipment 10

Organization and contacts 12

Connection to the TU Dresden 13

External project groups and branch offices 14

Networks 18

Institute in numbers (statistics) 22

Committees 24

The Fraunhofer-Gesellschaft at a glance 25

Fraunhofer Surface Technology and Photonics Alliance VOP 26

Research and development offers 28

Joining and surface treatment 28

Laser ablation and cutting, system engineering 38

Thermal coating 44

CVD thin film technology 50

PVD- and nanotechnology 56

Names, dates, events 64

Special events 64

Committees 66

IWS prizes in 2008 68

Diploma and doctoral theses 69

Participation in fairs and exhibitions 72

Patents 74

Publications 76

Conference presentations 82

Information service 88

Address and directions 89

Editorial notes 90


Highlights of 2008


Laser Institute of America distin-guished Professor Eckhard Beyer

On October 22nd 2008 the Laser Insti-tute of America (LIA) presented Professor Eckhard Beyer with theArthur L. Schawlow award. The awardis named after the Nobel Prize laureateand is the most prestigious recognitionin the field of laser technology. TheSchawlow award recognizes theaccomplishments of individuals whoprovided extraordinary contributions to the field of laser applications in science, industry and education.

Prof. Beyer receives the Schawlow Award 2008at the annual meeting of LIA during the ICALEO2008

Latest developments are presented at the 4th

fiber laser workshop in the International Con-gress Center Dresden

"Fraunhofer Project Center for Laser Integrated Manufacturing"founded in Wrocław

On September 24th

2008 and in thepresence of Dr. Angela Merkel,the Technical Uni-versity of Wrocławand the FraunhoferIWS signed a frame-work agreement tofound the joint"Fraunhofer ProjectCenter for LaserIntegrated Manufac-turing". Accordingto Dr. Merkel thecenter assumes a

vanguard role in applied research col-laboration between Germany andPoland. She recognizes the coopera-tion of "an excellent German photon-ics institute with one of the mostrenowned production technology insti-tutes in Poland" as an important build-ing block in neighborly relations.

Dr. Angela Merkel wishes Prof. Beyer success forthe establishment of the German-Polish researchcenter

4th international workshop "Fiber Laser"

The fourth international workshop onfiber lasers was held at the CongressCenter in Dresden on November 5th

and 6th 2008. The Fraunhofer IWSDresden organized the workshop. Inrecent years research and developmentin this area have made steady progress.Accordingly, the number of fiber laserapplications is continuously increasing.About 340 participants learned aboutnew possibilities of using fiber lasers inlaser materials processing applications.

Recognition of an innovativeprocess for the manufacturing ofairbag protection covers

On June 2nd 2008 the companySchreiner Protech received the "Inno-vation Award 2008" of the Free Stateof Bavaria for a new flexible process tomanufacture protective covers forairbags. Engineers at the FraunhoferIWS performed the basic technologyand system development of thisprocess.

Highlights of 2008


Diamor® coatings on thermal spraycoated ball valves

In 2008 the results of a joint researchproject with the company KVT Kurl-baum GmbH were commercialized inlow volume production. A Diamor®

top layer is applied as an overcoat to athermally sprayed hard metal coatingon ball valves. The coefficient of fric-tion in the valve is reduced to onethird and the lifetime of the ball valvesdrastically increases.

Temperature control system tobraze solar cells

The cooperation between the Fraunhofer IWS Dresden and the com-pany teamtechnik Maschinen undAnlagen GmbH Freiberg began in2007. Both partners developed a fastdetection and control system for tem-perature control applications. A systemthat had originally been developed forlaser hardening processes was adaptedto brazing of solar cells. The systemwas refined for 2008 and implement-ed in additional installations ofteamtechnik equipment.

Further commercialization of robotbased laser systems for hardeningand buildup welding

A subcontract from ALOtec DresdenGmbH in spring 2008 led the IWS toimplement a robot based laser-harden-ing system with a 6 kW diode laser atthe company EMO in Celje (Slovenia).The system is currently used to hardentools for body making. As a subcon-tractor the IWS was responsible for thedevelopment of the technology as wellas the delivery of special components.

In October 2008 IWS engineers inte-grated a 6 kW diode laser, includingsystem and process technology, into alaser buildup welding robot machinewith pivot and swivel axes at theGreek company Roussakis ShipRepairs. The system is used to repairvarious ship components. A highdegree of flexibility is ensured by the availability of a set of different powder nozzle configurations of theFraunhofer IWS COAXn family.

Installation of a robot based laser hardening system in Slovenia

The coating of balls for ball valves was commer-cialized in low volume production

Laser beam buildup welding of ship componentsat Roussakis Ship Repairs in Greece

Brazing system of the company teamtechnik Ma schinen and AnlagenGmbH Freiberg with anintegrated temperaturecontrol system from Fraunhofer IWS, upper pic.:optics with filter holder

Institute profile


Activity areas of the Fraunhofer IWS Dresden

Business fields

The IWS business fields are joining,cutting, and surface technologies. Inparticular are the following areas:

- joining,- removal and cutting,- surface technologies consisting of

· surface layer technologies,· thermal coating technologies,· PVD vacuum coating technologies,· CVD atmospheric pressure coating

technologies.

The business field "Surface Technol -ogies" primarily addresses wear andcorrosion protection, optical and deco-rative coatings, other functional coat-ings as well as the removal, structuringand repair of surfaces.

Laser and surface technologies areproduction technologies. A central ele-ment of production technologies ismaterials. Materials are constantlydeveloped and improved. Materials science plays an important role inmacro processing. Similarly, nanotech-nology is of fundamental importanceto thin film coating technologies. Inboth areas the institute created newand extended upon existing core com-petences. Due to the close cooperationwith equipment and system manufac-turers, the IWS is in the position tooffer "one stop solutions" to our cus-tomers. In general these solutions relyon novel concepts, which are based on an overall systems and processapproach that also considers materialsand workpiece behavior. The steadyexpansion of IWS equipment resourcesguarantees an effective and high-levelproject performance utilizing the latesttechnologies available.

Our Mission: We solve our customer's problems and consider projects as successful if our customers are earning money with the developed solution

Short portrait

The research and development work atthe Fraunhofer Institute for Materialand Beam Technology (IWS) is basedon our substantial expertise in mate -rials- and nanotechnologies combinedwith the resources for comprehensivematerials analysis and characterization.The specialty and competitive advan-tage of the Fraunhofer IWS lies in thecombination of this fundamentalexpertise with its far reaching experi-ences and resources in the areas ofcoating and laser technologies.

Surface and coating technologiesincreasingly involve plasma processes.Therefore the institute developed acore competence area in plasma coat-ing processes, which includes atmos-pheric pressure plasma sources andplasma CVD reactors.

In the area of laser technologies, theIWS focuses on laser materials process-ing and the development of laser spe-cific system solutions.

To fulfill our mission to develop newtechnologies for industrial customersand to support them during the tech-nology transfer, we developed a corecompetence in the area of systemtechnologies.

Institute profile


Laser materials processing

- high speed cutting of thick metalsheets

- cutting and welding of plastics andother non-metals

- development of welding processesfor hard-to-weld materials

- laser hybrid technologies such as· laser induction welding· laser induction remelting· plasma TIG or MIG assisted laser

welding- laser and plasma powder buildup

welding- laser surface layer hardening,

alloying, and remelting as well asshort-term heat treatment

- removal and cleaning- process monitoring and control

Internet: www.iws.fraunhofer.de

Plasma coating processes

- plasma, flame, and HVOF spraying- atmospheric pressure plasma assist-

ed CVD (microwave and arc jet plas-mas)

- plasma etching- development and adaptation of plas-

ma sources- vacuum arc processes- precision coating processes (mag-

netron and ion beam sputtering)- laser arc processes as hybrid tech -

nology

Systems technology

- utilization of the process know-howto develop, design and build compo-nents, equipment and systems thatcan be integrated in manufacturinglines including software components

- laser system solutions for cutting,welding, coating and surface refine-ment

- development of process monitoringand control systems

- process focused prototype develop-ment of coating systems or theircore modules

- components for PVD and CVD sys-tems

- atmospheric pressure plasma assist-ed CVD sources

- measurement systems for the char-acterization of coatings and the non-destructive part testing using laseracoustic and spectroscopic methods

- systems for the spectroscopic moni-toring of gas mixtures

- software and control techniques

Materials science, nanotechnology

- properties analysis of surface treat-ed, coated and welded materials andparts

- failure and damage analysis- optical spectroscopic characterization

of surfaces and coatings down tothe nanometer

- mechanical tribological characteriza-tion

- thermoshock testing of high temper-ature materials

- coating thickness and E-modulusmeasurements of nm to μm coatings

Our core competences:

Process simulation

The IWS develops complete modulesto simulate:

- thermal hardening and laser hardening,

- laser welding,- laser powder buildup welding,- vacuum arc coating,- gas and plasma flow dynamics in

CVD reactors,- optical properties of nano layer

systems.

The simulation results are used forprocess optimization. We also useadditional commercially available simu-lation modules.


2D cutting system with linear directdrive (max. 300 m min-1 feed rate)

3D cutting system with two processingoptics (synchronous and tandem pro-cessing)

2D and 3D cutting head systems forCO2, Nd:YAG and fiber lasers

two laser processing stations withindustrial robots

several precision systems with up to 8CNC axes in combination with severallaser beam sources

micro structuring systems with excimerlasers (193 nm and 248 nm)

Laser beam sources

several CO2 lasers, up to 8 kW

several fiber lasers, up to 8 kW cw

disk laser, 5 kW

TEA and sealed-off CO2 laser

several Nd:YAG lasers up to 4.4 kWcw (diode pumped) and 1 kW pm

Nd:YAG laser (1064, 532, 355 nm)with pulse lengths in the ns range

Nd:YAG laser with OPO (400 - 700 nm)

mobile Nd:YAG laser for surface struc-turing and cleaning

several high power diode lasers, 1 - 10 kW

fiber laser (16 mJ pm, 20 W cw)

excimer laser (193 nm and 248 nm)

Handling systems

3D double gantry system, 22 axes with 3D processing heads, speeds ofup to 40 m min-1, working space 10 x 3 x 1.5 m3

several CNC laser processing systemswith up to 8 axes, speeds of up to 20 m min-1, working space 4 x 3 x 1.5 m3

laser induction hybrid system with 5axes (6 kW CO2 laser, 80 kW MFinduction generator)

2D and 3D milling machines withretrofitted laser and plasma powderbuildup welding

laser system for the simultaneous pro-cessing with two cooperating robots,swivel unit and two fiber coupled 6 kW diode lasers

Laser beam welding system with 6 kW CO2 highpower laser

Coating systems

vacuum arc coating systems (laser arc,pulsed high current arc, direct currentarc, magnetic filter)

deposition systems for ultra precisionmultilayers based on ion beam sputter-ing and magnetron sputtering

combination coating system, electronbeam (40 kW) and high current arc

laser PVD coating system (Nd:YAG,excimer, TEA-CO2-laser) in high vacuum and ultra high vacuum

systems for atmospheric pressure plas-ma spraying (APS) and the high veloci-ty oxygen fuel (HVOF) thermal sprayingwith powders and suspensions

systems for the plasma assisted CVD atatmospheric pressure

system for plasma etching at atmos-pheric pressure

test stand for atmospheric pressureplasma sources (linear dc arc dis-charge)

Equipment

Institute profile

High-speed 3D laser cutting system with lineardrives

View of the IWS technology hall


Laser scanning microscope LSM Pascal 5 for high precision characterization and analysis ofsurfaces in the micro and nano meter range

Special components

static and flexible dynamic beam shap-ing systems for laser powers of up to10 kW

remote processing optics for CO2,Nd:YAG and fiber lasers with workingareas of up to 1 x 1 m2

CNC or sensor controlled wire feederfor laser welding and coating

mobile MF and HF induction sources (4 - 20 kHz, 100 - 400 kHz)

modular powder nozzle systemCOAXn for laser beam buildup weld-ing

process monitoring systems for ther-mal spraying, laser beam buildupwelding, laser welding and cutting

software package DCAM for theoffline programming of robots andCNC systems

sensor systems for the 3D geometryscanning (automatic teach in) for laserprocessing of parts (online and offlinecontour tracing)

beam diagnosis systems for CO2,Nd:YAG and fiber lasers

LOMPOC-Pro + EMAqs-camera

measurement system for high speedprocess analysis (4 channel high speedimage intensifying camera)

UV / VIS-, FTIR and NIR diode laserprocess spectrometer for the in-situanalysis of process gases and plasmas

Laboratory for the fabrication of single wall car-bon nanotubes

Institute profile

3 axes and 5 axes CNC milling machines withlaser processing modules for the complete ma -chining with laser buildup welding and milling

Measurement devices

equipment for the analysis of materialsmicrostructures including preparationtechniques:- metallography- transmission electron microscopy- scanning electron microscopy

equipment for materials testing:- servo hydraulic testing machines

(pull-pressure: ±500 kN and ±100 kN;torsion / axial: 8 kN / 40 kN)

- mechanical strain / compression testing machine

- computer assisted micro hardnesstester

- resonance fatigue tester- flat bending torsion system- several wear testers (abrasive, cavita-

tional, oscillating in sliding contact)- salt spray fog test

laser acoustic tester for the determina-tion of the E-modulus of coatings

laser shock measurement system withhigh speed pyrometer

equipment for analyzing surfaces andcoatings:- scanning atomic force microscope

(AFM)- EUV reflectometer- fully automated spectral ellipsometer

(270 - 1700 nm)- UV-VIS spectrometer- raman micro spectrometer- FTIR-NIR spectrometer- FTIR spectrometer, FTIR microscope- registering indenter- scratch tester- roughness measurement equipment - tribometer- intrinsic stress measurement equip-

ment

X-ray diffractometer (CuKα, MoKα)

particle counter (CPC + SMPS) andnano spectral analyzer

optical 3D coordinate measurementsystem

impedance spectrometer

Organization and contacts

Institute profile

Guest companies located at Fraunhofer IWS: - EFD Induction GmbH Freiburg, Dresden Branch- ALOtec Applied Laser and Surface System Technology GmbH

Dresden- AXO Dresden GmbH


Institute profile

Connection to the University of Technology (TU Dresden)

Cooperation Fraunhofer IWS - TUDresden

A special agreement regulates the co-operation between the IWS and theTU Dresden. Prof. Beyer works simulta-neously as the executive director ofthe IWS as well as a chairman at theUniversity. The work is distributed asfollows: Research and education areperformed at the university andapplied research and development areperformed at the IWS. IWS employeesare tied into projects at the universityand vice versa. In the end the IWS anduniversity form one unit with a dif-fer ent emphasis for each part.

The advantages for IWS are:- cost effective basic

research- education of junior scien-

tists for the IWS- access to scientific

helpers

The advantages for the TUare:- R&D involvement in industrial

projects- integration of newest R&D results

into education- training of

students on the most modern equip-ment


Chair for Laser and Surface Technology

During 2008, 34 colleagues wereemployed in the university depart-ment. The third party revenues yieldedmore than 1.0 million euros.

The department of laser and surfacetechnology is the driving componentof the institute for surface and manu-facturing technology at the faculty of mechanical engineering. The performed projects are more basicallyoriented and are intended comple-mentaryly to the work of the IWS. Theteams deal with following subjects:

- production design - laser technology- surface technology - film technology - adhesive bonding- ablation technology

The following courses were offered:- Prof. Beyer: Manufacturing techno -

logy II - Prof. Beyer: Laser basics - Prof. Beyer: Laser system technology - Prof. Beyer: Plasmas in manufactur-

ing techno logy - Prof. Beyer: Rapid prototyping- Prof. Beyer: Laser robotic, lasertronic- Dr. Leson: Nanotechnology - Prof. Schultrich: Thin film technology- Prof Günther: Micro and finish pro-

cessing

CD for laser technology course CD for plasmas in manufacturing technologycourse


External project groups and branch offices

Dr. Axel ZwickManager of the project groupat DOC in Dortmundphone: +49 (0) 231 844 3512

The ThyssenKrupp Steel AG (TKS) con-centrated its resources and compe -tences in surface technologies with theformation of the DOC in which theFraunhofer-Gesellschaft participates.

The DOC is the largest research anddevelopment center in the area of sur-face treatments for sheet steel in Europe. At DOC employees of TKS andthe Fraunhofer IWS work jointlytogether in a new form of cooperationcalled the "Public Private Partner -ship". A common goal is the develop-ment of innovative surface engineeringprocesses and their transfer to indus -trial manufacturing.

One early outstanding result of thiscooperation is a novel zinc alloy coat -ing (ZE-Mg). At only half the layerthickness, these new coatings combinethe very good corrosion protectiveproperties of proven zinc coatings with a substantially improved laserweldability.

In addition hybrid and combinationprocesses have been developed. Ofspecial note are the hybrid welding ofhigh strength steel components andthe combination processes of cleaningand welding and welding and postgalvanizing.

Beyond this the Fraunhofer projectgroup offers in its 1,100 m2 facility anumber of complementing surfacetechnologies. With modern equipmentit is possible to produce nearly porefree and extremely adherent plasmaspray coatings. Areas on componentsand tools facing aggressive wear canbe coated with millimeter thick wearprotection coatings through laserdeposition welding techniques. Meter-long and ton-heavy parts can be coated in vacuum with nano- andmicro meter high performance coatingssuch as the Diamor® film system,which provides an extreme surfacehardness and excellent low-friction sliding properties. Coating systems arebeing developed with additional corro-sion protection.

The wide spectrum of the availableprocesses and their combinationstogether with the expertise of theinvolved Fraunhofer Institutes guaran-tees cost effective and optimized prob -lem solutions for our customers,whether it is TKS, a TKS-customer, orany other company. With the help of anovel compact 8 kW solid-state laserwith high beam quality, it becomespossible to perform process develop-ment as well as "trouble shooting"directly on site at the industrial cus-tomer production facility.

www.iws.fraunhofer.de/doc

Industrial project group at the Dortmunder OberflächenCentrum(DOC) at the ThyssenKrupp Steel AG

Facility of the Dortmunder OberflächenCentrum



"To jointly shape the future" is thegoal of German and Polish engineersand scientists who are collaborating atthe "Fraunhofer Project Center forLaser Integrated Manufacturing". Inthe presence of Germany’s chancellor,Dr. Angela Merkel, the research centerwas officially inaugurated in Wrocławon September 24th 2008.

At the Fraunhofer project center, German and Polish researchers willbundle their know-how in a holisticapproach to further develop andimprove rapid prototyping technolo-gies. Fraunhofer IWS engineers areexperienced in the development oflaser technologies and the scientistsfrom the TU Wrocław are specialists inmanufacturing and process technolo-gies. Together they can explore anddevelop new technology areas. Thedevelopment of new prototyping tech-niques requires joint competences.

A series of joint projects is lined up.For example, one project will utilize alaser process to build structures, whichare mechanically finished in betweenand post processing steps in one andthe same machine setting. This andsimilar projects aim at the expansion

Prof. Dr. Edward ChlebusExecutive director of instituteTU Wrocławphone: +48 (0) 71 320 2705

Prof. Dr. Edward Chlebus, Prof. Dr. Eckhard Beyer and Prof. Dr. Hans-Jörg Bullinger in discussion withDr. Bogdan Dybala at the rapid prototyping laboratory of the TU Wrocław (from left to right)

of rapid prototyping to rapid manufac-turing with the ultimate goal to devel-op generating fabrication processes forindividualized manufacturing of uniqueproducts.

From Wrocław the team wants todevelop international markets. Potential customers for innovativerapid prototyping are automotive sup-pliers and manufacturers of householdand electro appliances in East andWest.

The partnership with the TechnicalUniversity in Wrocław represents thefirst Fraunhofer cooperation in Poland.The effort plays a vanguard role inestablishing German-Polish collabora-tions in applied research.

Fraunhofer Project Center for Laser Integrated Manufacturing(PCW)

Dr. Jan HauptmannProject coordinationFraunhofer IWSphone: +49 (0) 351 2583 236



Coating Technology Division

Prof. Jes Asmussen and Dr. ThomasSchuelke lead a group of experiencedFraunhofer researchers and Germanstudents in collaboration with facultymembers and students of the Michi-gan State University. The team worksin the following research areas:- technologies involving amorphous

diamond-like carbon coatings,- chemical vapor deposition of ultra-

nano-, poly- and single crystallinediamond materials,

- doping of diamond materials,- physical vapor deposition technolo-

gies.

The amorphous diamond-like carboncoating research program utilizes theLaserarc® process, which was devel-oped at the IWS Dresden. Since severalyears CCL engineers have been apply-ing this technology to coat tools forthe ma chining and processing of aluminum materials. The amorphousdiamond-like carbon coating signifi-cantly improves the lifetime of thesetools. The Coating Technology Divisioncollaborates closely with MichiganState University’s Formula RacingTeam. High performance wear resis-tant coatings are tested on variousracecar components under race conditions. The collaboration providesthe racing team with a competitiveadvantage and also returns criticalinformation to CCL engineers forimproving coating performance.

The US market is one of the mostimportant international benchmarksand innovation driving forces forapplied research and development.Since 1997 the Fraunhofer IWS Dresden has been concentrating itsUSA activities within the "FraunhoferCenter for Coatings and Laser Appli -cations" (CCL).

The Fraunhofer Center for Coatingsand Laser Applications mirrors themain activities of the IWS in laser andcoating technologies. With an annualturnover of $4.4 Mio the center is one of the strongest Fraunhofer cen-ters in the USA. Since 2003, Dr. JesAsmussen heads the CCL. He is a pro-fessor at Michigan State University andhis previous work in diamond coatingsand synthesis ideally complement theknow-how of the Fraunhofer IWS inthe area of Diamor® coatings.

The CCL consists of two divisions, the "Coating Technology Division" atthe Michigan State University in EastLansing and the "Laser ApplicationsDivision", which is situated at theFraunhofer USA Headquarters locationin Plymouth, Michigan.

Prof. Jes AsmussenCenter DirectorCCL / USAphone: +1 (0) 517 355 4620

Fraunhofer Center for Coatings and Laser Applications (CCL)

www.ccl.fraunhofer.org



In recent years the Coating TechnologyDivision focused on research in thearea of microwave plasma assistedchemical vapor deposition of diamondmaterials and in particular on the syn-thesis of doped and undoped singlecrystalline diamond. Here the teamestablished an international reputation. Due to the tight integration in the Uni-versity structure the team also offersanalysis services for materials composi-tion and the characterization of coat-ing and component.

Laser Applications Division

The laser group of the CCL is locatedin Plymouth (Michigan), which is "nextdoor" to the American automotiveindustry in Detroit. The group per-forms numerous laser beam weldingprojects of power train componentssuch as differential gear sets, transmis-sions and drive shafts. In 2007 theCCL was presented with the HenryFord Technology Award in recognitionfor the development of a laser beamwelding process to improve the roofstrength of Super Trucks.

A highlight of the research work is thedevelopment, patenting and licensingof a laser buildup welding process togenerate highly abrasion resistantcoatings. The coating consists of nearlymm-sized synthetic diamond particles,which are embedded in a metallicmatrix. The technology is applied todrilling equipment for the oil produc-tion in the USA and Canada.

The close connection to the Fraun-hofer CCL offers several advantages tothe IWS. The awareness of the supplyand demand situation helps to quicklyrecognize trends in the United States,which influence the technology devel-opment efforts at the IWS.

The research and development workperformed in the United States gener-ates additional know-how and compe-tencies, which benefit the projectacquisition in German and Europeanmarkets. An exchange program offersIWS researchers the opportunity towork in the United States, which pro-vides them with experiences that arebeneficial for their entire career.

Building of CCL, CLT (Center for Laser Tech -nology), and Fraunhofer USA Headquarters inPlymouth, Michigan

Building of CCL in East Lansing, Michigan

Dr. Thomas SchülkeDivision ManagerCoating Technologyphone: +1 (0) 517 432 8173

Craig BrattDivision ManagerLaser Applicationsphone: +1 (0) 734 738 0550


Networks

Nanotechnology competence center

Nanotechnology competence cen-ter "Ultrathin Functional Films"

Nanotechnology belongs to the keytechnologies of the 21st century.Already today there are products readyfor the market. Examples include com-puter hard disk drives and read / writeheads for data storage, which arecoated with layers only a few nanome-ter thick. Another example is the scan-ning electron microscope that makesthe world of atoms and molecules visi-ble. Ultrathin films are a key elementof nanotechnology.

Since September of 1998, 51 compa-nies, 10 university institutes, 22research institutions and 5 associa-tions, who bundled their know-howand formed a resources network, joint-ly pursue the persistent developmentof industrial application opportunities.The Fraunhofer IWS coordinates thiseffort, which is recognized by the German Federal Ministry for Educationand Research as a national compe-tence center for ultrathin functionalfilms.

In February 2007, a group of ninecompetence centers with a focus innanotechnology joined forces by form-ing the "Working group of nanotech-nology competence centers in Ger-

many (AGeNT-D)".The participating cen-ters are located acrossGermany and jointlycover the entire areaof different nanotech-nologies.

Project coordination

Dr. Andreas Lesonphone: +49 (0) 351 2583 317 [email protected]

Dr. Ralf Jäckelphone: +49 (0) 351 2583 444 [email protected]

website: www.nanotechnology.dewww.iws.fraunhofer.de

Participation of the nanotechnolo-gy competence center Dresden atthe Nanotech 2008 exhibition andconference in Tokyo

The nanotechnology competence cen-ter supported Saxony’s EconomicDevelopment Corporation to exhibit atthe worldwide largest nanotechnologyshow "Nanotech Tokyo 2008" fromFebruary 13 - 15, 2008. The "WorkingGroup of Nanotechnology Compe-tence Centers in Germany" (AGeNT-D)presented in Tokyo as well.

Over three days 49,400 visitors attend-ed the exhibition, which marked anew record. In the area of nanotech-nology the Federal Republic of Ger-many supports coordinated efforts ofcompanies to participate in overseasexhibitions. For the third time Germanindustry used this opportunity at theNanotech 2008. Saxony’s EconomicDevelopment Corporation enriched theprogram by organizing accompanyingevents such as a seminar on "High-lights of Germany’s latest nanotech-nology in Saxony presented by youngscientist". Several members of theNano-CC actively participated withpresentations at the conference.

The Fraunhofer IWS and companies present technologies and products atthe booth of Saxony’s Economic Development Corporation

Interested visitors at the AGenT-D booth receiveinformation


Networks


Dr. Andreas Lesonphone: +49 (0) 351 2583 317 [email protected]

Dr. Otmar Zimmerphone: +49 (0) 351 2583 257 [email protected]

website: www.iws.fraunhofer.de/ innovationscluster

Nanotechnology innovation cluster "nano for production"

Nanofair career forum: Attentive listeners duringthe technical presentations.

Nanotechnology innovation cluster"nano for production"

From the automotive to the medicaldevice industries – all branches canprofit from nanotechnologies. Germanresearchers and industries cooperateto accelerate the development ofapplications of these technologies. TheDresden region is a successful locationfor nanotechnology innovation. Herecompanies and researchers collaboratein the innovation cluster "nano forproduction". The goal of the innova-tion cluster is to advance nanotechnol-ogy related basic research resultstoward commercialization. In addition,the cluster develops and evaluatesessential elements of nanoproductiontechnology and makes them accessibleto a wide range of potential users.

The innovation cluster’s core activitiesprovide education events and supportfor joint projects to commercialize scientific research results. An exampleis the collaboration of several compa-nies and research institutions with thecompany Q-Cells to introduce atmos-pheric plasma processes in the manu-facturing of solar cells. Within thiscooperation several projects have beensuccessfully worked on. The currentfocus is on establishing a pilot produc-tion line applying the new processes,which will be launched in 2009.

"nano for production" at the Hannover Tradeshow

"nano for production" and six otherinnovation clusters joined forces at theHannover Tradeshow presenting theirresults at a Fraunhofer booth. Thestate government of Saxony in collabo-ration with the innovation cluster"nano for production" organized aSaxon-Japanese evening event tointensify existing and establish newcontacts. Nanotechnology was one ofthe evening main topics.

Nanofair and Nanofair careerforum

Participants and presenters fromEurope, Japan, North America, Aus-tralia and Mexico met at the congresscenter in Dresden to join technical presentations and discussions aboutnano technologies. The technical pre-sentations were structured into severalevents. On March 10th 2008 the"Nanofair Career Forum" offered stu-dents the opportunity to inform them-selves about career options in thisarea.

The president of the Fraunhofer-Gesellschaft,Prof. Bullinger, visits the booth of the innovationcluster "nano for production"


Networks

Laser integration in production technologyInitiative LiFt

Project Goal

The goal of this network is to pointout potential opportunities and offerservices to machine builders and man-ufacturers. The potential advantagesare:

- time and cost savings by shorteningprocess chains,

- increase efficiency of manufacturingprocesses and products,

- unique selling features at the highesttechnology level.

The initiative

The LiFt initiative aims at applying lasertechnologies to secure and expand thecompetitiveness of Saxony’s machineand plant engineering and buildingindustries. The initiative was launchedin 2007 when the concept won theinnovation competition "Industrymeets Science", which was sponsoredby the Federal Ministry of Transporta-tion, Building and Urban Affairs(BMVBS).

Within the LiFt initiative the FraunhoferIWS Dresden cooperates with the Uni-versity of Applied Sciences in Mittwei-da and the Institute for InnovativeTechnologies, Education and Continu-ing Education (ITW) e.V. in Chemnitz.The institutions aim at commercializinginnovations in the area of laser materi-als processing.

Integration concepts

The requirements for process chainoptimizations vary by manufacturer. Alow volume production scenario typi-cally requires a maximum of flexibility.High volume manufacturing on theother hand, often focuses on costoptimization. These varying require-ments result in a wide variety of inte-gration concepts:

- Direct integration into a machine formechanical processing. This is a solu-tion when the laser processing timeis short compared to the cycle timeof mechanical processing. In somecases it is possible to sequentially uti-lize the laser at several machines.

- Cycle time parallel integration isused when the laser processing timeis comparable to the time requiredfor mechanical processing.

The laser can be integrated in almostany conventional process chain toshorten the manufacturing time.

Laser integration in manufacturing with strongSaxon partners

As developers of technologies andeducators, the LiFt project partnersoffer their services to small and medium sized companies not only inSaxony but also in other regions.


Networks


Dr. Steffen Bonßphone: +49 (0) 351 2583 201 [email protected]

Mrs. Claudia Zellbeckphone: +49 (0) 351 2583 332 [email protected]

website: www.laserintegration.dewww.iws.fraunhofer.de

The project is funded by the Federal Ministry forTransport, Building and Urban Affairs (contractnumber 03WWSN019).

Activities

The LiFt initiative was introduced atseveral tradeshows such as the IntecLeipzig, SIT Chemnitz, Hannover Indus-try Tradeshow and the specializedLasys show on system solutions in lasermaterials processing. Jointly with theGerman Society of Tool and Die Makers, the LiFt initiative exhibited atthe Fakuma tradeshow in Friedrichs -hafen. Innovative tool making solu-tions and holistic process chainapproaches were introduced at theEuromold tradeshow.

Engineers from the area of Saxonyappreciated the offer to participate inthe event "Process efficiency throughlaser integration" and to learn aboutthe latest possibilities of laser manu-facturing integration. The network wasintroduced at the 5th meeting of theautomotive cluster Southwest Saxonyas well as at events of engineering ser-vice companies such as the "innova-tion evening" hosted by the companyEuro Engineering.

Designers, manufacturing planners andCEOs are interested in technologytransfer in the area of laser materialsprocessing. A highlight was the 7th

workshop on "Industrial Laser Applica-tions of High Power Diode Lasers"hosted by the Fraunhofer IWS Dres-den. Here Laser manufactures, indus-trial users and laser technology devel-opers met to discuss their experienceswith a focus on the integration of lasertechnologies in manufacturing.

The LiFt iniative exhibits at the Fakuma tradeshow

Demand analysis

A special database was developed togather information on possibilities anduser demands for potential laser appli-cations. All project partners despitetheir different IT guidelines can usethis database. Interested users havethe option to easily contact projectpartners. Using a simple form, theycan describe their needs and explainthe technology interests and specialcircumstances. Laser experts willrespond and contact the interesteduser.

Consulting and testing

Consulting as a core project activity isbased on already installed solutions aswell as on individual requirements. Inaddition to information and consultingservices the project also provides limit-ed testing services.

Andreas Wessel-Terham (BMVBS) and WilfriedWascher (PtI) during the 1st status seminar"Industry meets science" on November 12 / 132008 at the IWS Dresden

Building 8400 m2

- processing technology areas 2000 m2

- lab space, workshops 3070 m2

- office space 2630 m2

- conference rooms, seminar rooms etc. 700 m2

Technology area at the DOC (Dortmund) 1100 m2

Institute in numbers

Total employees

The TU Dresden (chair for laser and surface technology) and the Fraunhofer IWSare connected through a cooperation agreement. A number of universityemployees are working closely with IWS employees on joint projects. Basic re -search is conducted at the university; application related process developmentand system technical work is done at IWS.

For 2008 the employees are divided up as follows:

Employees of Fraunhofer IWS

Number Staff 127 - scientists 69 - technical staff 49 - administrative staff 9

Apprentices 10

Research assistants 104

Employees CCL USA 16

Total 257

Employees of Chair for Laser andSurface Technology of TU Dresden

Number Staff 34 - scientists 28 - technical staff 5 - administrative staff 1

Research assistants 17

Total 51


Budget and revenue 2008 (preliminary*)

million € Operational costs and investments 2008 18.5

Budget 16.4 - personnel costs 8.3 - other expenses 8.1

Investment 2.1

million € % Revenue 2008 18.5

Revenue operations 16.4 - industrial revenues 7.7 47 - revenues of public funded projects 3.5 21 - base funding IWS 5.2 32

Revenue investment 2.1 - industrial revenues 0.1 - revenues of public funded projects - - base funding IWS 1.3 - strategic investment 0.7

Projects

In 2008, IWS handled 277 projects. The distribution of the projectswith respect to their volume is shown in the graphic below. One hun-dred thirty one of the projects were for 10 to 50 T€ (thousands ofeuro), for example.

Institute in numbers



Committees

Institute management committee

The institute management committeeadvises the executive director and participates in decision making con cern -ing the research and the business policyof IWS.

Members of the committee are:Prof. Dr. E. Beyer Executive directorDr. A. Leson Deputy director Dr. A. Techel Deputy director

Head of ad minis -tra tion

Prof. Dr. B. Brenner Department head Dr. S. Kaskel Department headDr. L. Morgenthal Department head

Guests are: Prof. Dr. U. Günther Agent of the

chair / universityDr. U. Klotzbach Office manager

VOPDr. A. Wetzig Department head

(since Jan. 2009)

Board of trustees

The advisory committee supports andoffers consultation to the FraunhoferIWS. Members of the advisory committee in 2008:

P. Wirth, Dr. Chairman of Rofin-Sinar Laser GmbH, committee chair

R. Bartl, Dr. Manufacturing management ofSiemens AG Transportation Systems

I. Bey, Dr.Research management Karlsruhe

T. Fehn, Dr.General manager Jenoptik Laser, Optik, Systeme GmbH

D. Fischer, Mr.General manager EMAG LeipzigMachine Factory GmbH

U. Jaroni, Dr. Member of the board of directors -automotive division - ThyssenKruppSteel AG

F. Junker, Dr. Member of the board of directors ofthe Koenig & Bauer AG,

H. Kokenge, Prof.President of the Dresden University ofTechnology

T. G. Krug, Dr.Managing director Hauzer TechnoCoating BV, Niederlande

P. G. Nothnagel, Mr. Saxony Ministry of Economic Affairsand Labor

H. Riehl, Dr. Federal Ministry of Education andResearch, manager of the productionsystems and technologies department

R. Ruprecht, Dr. Manager of the Research Center Karls -ruhe (project performing institution)and the production and manufacturingtechnologies section at the ResearchCenter Karlsruhe GmbH

R. Zimmermann, Dr. Saxony Ministry of Science and Art

Scientific technical council (WTR)

Scientific technical council of theFraunhofer-Gesellschaft supports andadvises divisions of the Fraunhofer-Gesellschaft with regard to technicaland scientific policy. The council con-sists of members of the institute man-agement and an elected repre sent ativeof the scientific and technical staff ofeach institute. IWS members of WTRin 2007 were:- Prof. Dr. E. Beyer - Dr. S. Bonß

The 18th committee meeting took place on February 14, 2008, atFraunhofer IWS in Dresden.


The Fraunhofer-Gesellschaft at a glance

The Fraunhofer-Gesellschaft

Research of practical utility lies at theheart of all activities pursued by theFraunhofer-Gesellschaft. Founded in1949, the research organizationundertakes applied research that driveseconomic development and serves thewider benefit of society. Its services aresolicited by customers and contractualpartners in industry, the service sectorand public administration.

At present, the Fraunhofer-Gesellschaft maintains more than 80research units in Germany, including57 Fraunhofer Institutes. The majorityof the 15,000 staff are qualified scien-tists and engineers, who work with anannual research budget of €1.4 billion.Of this sum, more than €1.2 billion is generated through contract re -search. Two thirds of the Fraunhofer-Gesellschaft’s contract research rev-enue is derived from contracts withindustry and from publicly financedresearch projects. Only one third iscontributed by the German federaland Länder governments in the formof base funding, enabling the insti-tutes to work ahead on solutions toproblems that will not become acutelyrelevant to industry and society untilfive or ten years from now.

Affiliated research centers and repre-sentative offices in Europe, the USAand Asia provide contact with theregions of greatest importance to pre-sent and future scientific progress andeconomic development.

With its clearly defined mission ofapplication-oriented research and itsfocus on key technologies of relevanceto the future, the Fraunhofer-Gesellschaft plays a prominent role inthe German and European innovationprocess. Applied research has a knock-on effect that extends beyond the

direct benefits perceived by the cus-tomer: Through their research anddevelopment work, the FraunhoferInstitutes help to reinforce the compet-itive strength of the economy in theirlocal region, and throughout Germanyand Europe. They do so by promotinginnovation, strengthening the techno-logical base, improving the acceptanceof new technologies, and helping totrain the urgently needed future gen-eration of scientists and engineers.

As an employer, the Fraunhofer-Gesellschaft offers its staff the oppor-tunity to develop the professional andpersonal skills that will allow them totake up positions of responsibilitywithin their institute, at universities, inindustry and in society. Students whochoose to work on projects at theFraunhofer Institutes have excellentprospects of starting and developing acareer in industry by virtue of the prac-tical training and experience they haveacquired.

The Fraunhofer-Gesellschaft is a recog-nized non-profit organization thattakes its name from Joseph von Fraun-hofer (1787–1826), the illustriousMunich researcher, inventor and entre-preneur.


Fraunhofer Surface Technology and Photonics Alliance VOP

top: Fraunhofer FEPmiddle: Fraunhofer IPMbottom: Fraunhofer ILT

Participating Fraunhofer institutes

Applied Optics and Precision Engineering IOFwww.iof.fraunhofer.de

Electron Beam and Plasma Technology FEPwww.fep.fraunhofer.de

Laser Technology ILT www.ilt.fraunhofer.de

Physical Measurement Techniques IPMwww.ipm.fraunhofer.de

Surface Engineering and Thin Films ISTwww.ist.fraunhofer.de

Material and Beam Technology IWSwww.iws.fraunhofer.de

The institutes of the Fraunhofer-Gesell-schaft have organized themselves intoseven research alliances, each speciali-zing in a specific area of technology, in order to promote collaboration inrelated disciplines and offer customersa unique source of coordinated jointservices.

Fraunhofer Surface Technology andPhotonics Alliance

Surface technology and photonics aretwo of the core competences of theFraunhofer-Gesellschaft. The former isof essential importance in the manu-facture of optical and optoelectroniccomponents and products. The latter,and laser technology in general, isbecoming increasingly common in pro-duction processes and metrology inconnection with surface engineering.They are both key technologies, beingemployed to a growing extent in avariety of applications, including pro-duction systems, optical sensors, infor-mation and communication technolo-gy, and biomedical engineering.


Fraunhofer Surface Technology and Photonics Alliance VOP

In order to coordinate the targetedapplication of their expertise anddefine joint strategy plans, six Fraunhofer Institutes employing a totalof around 1080 staff and workingwith a budget of €86 million havejoined forces in the Fraunhofer SurfaceTechnology and Photonics Alliance(VOP). The core competences of thealliance lie in the development of thin-film systems and coating processes fora wide variety of applications, surfacefunctionalization, the development oflaser sources and micro-optical andprecision-engineered systems, materi-als processing and optical metrology.

In the immediate future, the allianceintends to focus its research activitieson the advanced development of inno-vative laser sources such as fiber lasersand to nurture the industrial deploy-ment of terahertz technologies.

Chairman of the alliance:

Prof. Dr. Eckhard Beyer

phone: +49 (0) 351 2583 324fax: +49 (0) 351 2583 [email protected]

Fraunhofer-Institut für Werkstoff- und Strahltechnik IWSWinterbergstraße 2801277 Dresden

top: Fraunhofer ISTmiddle: Fraunhofer IOFbottom: Fraunhofer IWS

FEP

IWS

IOF

IST

ILT

IPM

Central office:

Dr. Udo Klotzbach

phone: +49 (0) 351 2583 252fax: +49 (0) 351 2583 [email protected]

Fraunhofer-Verbund Oberflächen-technik und PhotonikWinterbergstraße 2801277 Dresden

website: www.vop.fraunhofer.de

Editor: You always emphasize thatyour department attaches a special value to holistic solutions. How is thisreflected?

Prof. Brenner: Yes indeed, in shortthis concept implies an all-encompass-ing approach when developing solu-tions. In detail this means to us thatwe consider three influencing factorsas most essential for the effective fab-rication of new and value addingproducts: materials – technology –component performance. The rele-vance of these factors needs to becomprehensively understood and pur-posefully utilized.

Let me illustrate this approach basedon one of our most important areas:the laser beam welding of powertraincomponents for automobiles andtrucks. Here we are meanwhile crackfree laser welding materials and mater-ial combinations that were considerednon-weldable only a few years ago.There are no specific data availablethat describe the static and cyclic load-ing performance of welded joints frommaterial combinations such as steel /cast iron. This difficulty arises due toseveral factors such as the multidimen-sional loading and that the formationof residual stresses strongly dependson the part geometry, the weldingparameters, and the weld seam loca-tion and the welding processingsequence. Additionally, the static andcyclic component strength increasinglydepends on the material as well as thehardening of the weld seam, whichmakes it difficult to estimate its orderof magnitude. The automotive industryuses transmission test stands. How -ever, these tests are expensive andtypically the weld seams are not criticalduring part failure. As a result, a non-tolerable uncertainty remains whendesigning laser welded powertrain

components. Subsequently thesewelds are substantially over dimen-sioned. On the other hand, we alsoknow from failure analysis aboutpainful surprises during prototypemanufacturing. From 2009 on we willbe able to improve the situation. Wedesigned and built a special axial tor-sion test stand to be able to test theloading and strength limitations oftransmission typical laser welded jointsunder realistic conditions. Subsequent-ly we will be able to develop conceptsfor the optimized dimensioning ofwelded powertrain components.

Editor: What is new in the other mainarea, surface technologies?

Prof. Brenner: In 2008 we made amost important development step byintegrating laser beam hardening intoa machine tool. We believe that thiswas possible as a result of the confi-dence that our customers have in ourperformance. Together with projectpartners we designed and implement-ed an industrial manufacturing unitconsisting of two automated lathes, acentral high power diode laser, anintelligent beam delivery switch and anadditional laser hardening station forspecial geometries.

The laser beam hardening of hydrauliccomponents runs at close to identicalcycle times using the second spindle ofa rod turning machine. After the laser-hardening step the part is being fin-ished in the very same machine. Weconsider this industrially successfulsolution as a very important stepbecause it opens the door to a multi-tude of similar opportunities to costeffectively integrate laser beam hard-ening into cutting and formingmachine tools.

R&D-offer: Joining and surface treatment


A challenge is the best motivationPeter Ebeling



Prof. Dr. Berndt Brenner Department head(phone: +49 (0) 351-2583-207,[email protected])

Dr. Steffen Bonß Team leader surface treatment technologies (phone: +49 (0) 351-2583-201,[email protected])

Optimized technologies for thehardening of steel componentsthrough laser and / or induction

If conventional hardening technologiesare not suitable because of certaingeometric shapes, material and wearconditions, laser hardening can be ideal to produce wear-resistant partswith an increase in service life. Thistechnology is especially suitable for theselective hardening of multi-dimensionfaces, inner or hard to reach surfaces,sharp edges steps, bores and grooves,as well as for low distortion hardening.With a strong foundation of long termexperience in the broad fields of wearprotection and hardening, we are ableto offer:

- development of surface hardeningtechnologies with high power diodelasers, CO2 lasers, Nd:YAG lasersand / or induction,

- prototype, process and system optimization.

Dr. Jens StandfußTeam leader welding (phone: +49 (0) 351-2583-212,[email protected])

Welding of hard to weld materials

Laser welding is a modern weldingprocess that is widely utilized in in -dustry, especially in mass production.Such welding with a laser using anintegrated heat treatment cycle, devel-oped at IWS, offers a new process forthe manufacturing of crack-free welded joints of hardenable steels,austenitic steels and special alloys.With our extensive experience in metalphysics and an unique welding stationwith our integrated heat treatmentprocess, we are able to offer:

- development of welding technolo-gies,

- prototype welding,- process and system optimization,- preparation of welding instruction.

Laser beam welded Al-Cu joints for solar panelsProcess development for the loading adaptedlaser beam hardening



Example of projects 2008

1. Integration of laser beam harden-ing in high performance turning machines 32

2. Process technology solutions for laser beam welding of powertrain applications 34

3. An innovative torsion-axial testingsystem to evaluate laser weldedpower train components 36

Dr. Johannes RödelTeam leader materials characterization (phone: +49 (0) 351 2583 384,[email protected])

Complex materials and componentcharacterization

The control of modern joining and surface engineering processes requiresknowledge from structural changes tothe result ing component properties.Based on long term experience andextensive equipment in the area ofstructural, microanalytical and mechanical ma terials characterizationwe offer:

- metallographic, electronmicroscopic(SEM, TEM) and microanalytical(EDX) characterization of themicrostructure of metals, ceramicsand compound materials,

- determination of material data forcomponent dimensioning and quality assurance,

- property evaluation of surface treated and welded components,

- strategies for materials and stressadapted component design,

- failure analysis.

Dr. Irene JansenTeam leader bonding(phone: +49 (0) 351-463-35210,[email protected])

further information:www.iws.fraunhofer.de/projekte/001/e_pro001.htmlwww.iws.fraunhofer.de/branchen/bra01/e_bra01.html

Combination of remote laser welding and adhesive bonding

Servo hydraulic axial torsion test stand in action

Surface pretreatment and construc-tive adhesive bonding

An adhesive bonding process includesa step to treat the mating surfaces ofthe parts prior to applying the adhe-sive. The goal is to achieve good wet-ting of these surfaces with the adhe-sive and thus to generate a highstrength bond. We are using primarilyplasma and laser technologies in thisarea. The surfaces and the bondedcompounds are then being character-ized by contact angle, roughness andthickness measurements, optical micro -scopy, SEM / EDX and spectroscopicmethods. A new direction is to inte-grate carbon nanotubes into the ad -hesives, which can increase the bond-ing strength and / or provide electricalconductivity to the compounds.We offer the following services:- pretreatment of mating surfaces and

characterization of the surfaces,- constructive adhesive bonding of

various materials,- measuring the bonding strength and

aging behavior of adhesive bonds.



Fig. 3: Image from a process animation, whichshows a situation during the hardeningprocess in a pneumatically deliveredprotection chamber with laser beamand pressurized air nozzle operation

Task

The availability of high power diodelasers and a number of recently devel-oped system technology solutionshelped to establish laser beam harden-ing as a potential process to locallyprotect parts from wear in addition toclassical hardening methods. Likemany heat treatment processes, laserbeam hardening is typically appliedoutside of the main manufacturingprocess chain. However, manufactur-ers prefer a continuous part flow with-out additional logistics and storage tosave time and costs. Here the laserbeam hardening offers excellentopportunities.

A leading specialist for drive and con-trol technologies required the partialhardening of the outer surface of avalve for mobile hydraulic applications(Fig. 1). Conventionally the companyused an induction hardening processwith subsequent tempering. The partswere initially processed in a soft state,and then heat-treated and finally fin-ished in a hardened state. The overallprocessing from the raw material tothe finished valve took approximately20 hours. It was therefore difficult forthe manufacture to quickly respond to

Integration of laser beam hardening in high performance turningmachines

Solution

Initial tests proved successful to laserharden the hydraulic components. Indiscussions with the client it wasagreed that the favored solutionwould be to integrate the laser beamhardening process right into the turn-ing machine (Fig. 2). Since themachine has two spindles it is possibleto continue the turning operationalmost throughout the entire laserhardening process. The optical pathand the process chambers are keptclean by pressurized air and the laserprocess can be performed simultane-ously with the wet cutting operation(Fig. 3). The new technology processesparts from the rod. First the soft pro-cessing is performed on the main andthe opposite spindles. Then the hard-ening process and the hard processingare performed in the very same set-ting. The part leaves the machine afterit is fully processed and moves on toassembly. Fig. 1: Typical application of mobile hydraulics

made by Bosch Rexroth AG

Fig. 2: Benziger turning machine with integrat-ed laser optics in the drive chamber(left)

changes in demand. This was compen-sated by sufficient inventory. The pro-duction process was also based onbatches, which required numerouslogistic steps. The investment goal wasto find solutions that would overcomethese limitations while maintaining thepart quality.



Results

During the valve manufacturing thelathes machine processes unalloyedsteel. The laser treatment affectsapproximately half the wall thicknessof the part, leaving only a small mater-ial volume underneath the hardenedzone. To nevertheless achieve therequired material performance underthese conditions, the engineers imple-mented a self-quenching effect, whichis a common method applied duringlaser beam hardening processes. Com-pressed air is blown at the processedpart to assist self-quenching.

Fig. 4: System installation consisting of a fiber coupled high power diode laser, a controller cabinetfor the laser beam splitter and process controller "LompocPro", and two turning machinesand inter gas hardening machine

Process management

The laser beam hardening process usesa fiber coupled high power diode laserand is performed while the part isrotating. One laser shot hardens a ringshaped zone around the part withoutleaving a soft spot. During the processthe surface temperature is measuredwith the camera based temperatureacquisition system "E-MAqS" (Fig. 5).The data are supplied to the controllermodule "LompocPro", which in turnregulates the laser power to maintaina constant surface temperature. Thecomplete manufacturing line consistsof two turning machines with integrat-ed hardening modules. An additionalmachine hardens other parts belong-ing to the same assembly in an inertgas atmosphere. The laser is located inthe center between the othermachines and the beam is distributedto those machines using a beamswitch. An intelligent switch controlleroptimizes the beam delivery based onthe processing time of each turningmachine to minimize downtimes (Fig. 4). The process uses only a single

Fig. 5: The laser optics with temperature acqui-sition system "E-MAqS" is located inthe drive compartment of the turningmachine

Contact

Dr. Steffen Bonßphone: +49 (0) 351 2583 201 [email protected]

"LompocPro" controller that quicklyswitches between processes. All criticalprocess and calibration data arestored. The individual components areconnected using a profi-bus system.This concept allows the efficientexchange of messages between thelaser, the machine tools, the switchcontroller and the overall process con-troller.



Solution

The reliable and crack-free joining ofpowertrain components requires laserbeam welding processes that areadapted to the specific materials. Pri-marily the processes are designed toavoid cold cracking in materials with ahigh carbon content and limited weld-ability. There are two principleapproaches to tailor the process. Oneapproach is to adjust the temperature-time relationship during the process.This influences the phase transforma-tion timing of the materials and helpsto suppress the formation of brittlephases (laser induction welding). Asecond approach is to use additionalmaterial specific filler materials. Thesecan also be designed to achievedefined mixing ratios when weldingdifferent materials (alloy welding).

Process technology solutions for laser beam welding of powertrainapplications

Task

Transmission components consist ofshafts with mechanically mounted orwelded components such as gears,cams, clutch parts, cardan forks, andothers. These components are typicallymanufactured from hard-to-weldmaterials such as heat-treatable andcasehardening steels. Thus these mate-rials make it extremely difficult to usemodern joining technologies such aslaser beam welding. From the view-point of weldability several factorshave to be considered (Fig. 1).

The implementation of welding tech-nologies for transmission applicationstypically has to overcome the followingchallenges:

- materials with strongly limited weld-ability or combinations of differentmaterials (Fig. 2),

- risk of crack formation in stiff com-ponents due to the limited possibilityfor shrink relaxation in axial andradial weld seams,

- temperature sensitive weld seamregion, for example in hardenedgears (Fig. 3), bearing surfaces,

- high cyclical and dynamical loadrequirements for the application.

These complex challenges require tailored solutions that address specificmaterials and components.

Fig. 1: Factors that influence weldability

Fig. 3: Casehardened gear close to the weldseam

Fig. 4: Principle of laser induction welding

Fig. 2: Example of a mixed joint welded fromcast iron and casehardened steel

1 mm



Results

Martensitic hardenable carbon steelscan be crack-free laser welded using acoupled process of laser beam weldingand short-term localized inductiveheating. The localized heating sup-presses the formation of the marten-sitic phase and thus reduces the risk ofa delayed crack formation when thepart cools down (Fig. 4). This processcombination can be applied to numer-ous materials such as heat treatable,casehardening and induction harden-able steels that are used in powertrainapplications (Fig. 5).

However, there are also many compo-nents that exclude the possibility ofusing the localized induction heatingassisted laser beam welding processdue to material or design reasons. Anexample is the joining of differentialtransmission cases made from cast ironwith casehardened gears, which can-not be done with conventional weld-ing methods. Here a ductile and crack-free high performance laser beamwelded joint can be achieved by usingspecial filler materials in the area ofthe weld seam (Fig. 6).

Fig. 5: Examples for laser beam welding in the field of powertrain applications

Both laser beam welding process varia-tions have been tested and demon-strated in numerous industrial applica-tions. The induction heating and fillermaterial assisted laser beam weldingprocesses offer cost efficient possibili-ties to weld numerous powertraincomponents and to replace conven-tional mechanical joining techniques(Fig. 7).

A new advantageous solution for thecrack-free welding of casehardenedcomponents avoids thecostly removal of thecasehardened layer. Thislayer is instead removedduring the process withan integrated laser abla-tion step prior to thelaser beam weldingprocess with filler materi-als.

Contact

Dr. Jens Standfußphone:+49 (0) 351 2583 212jens.standfuß@iws.fraunhofer.de

Fig. 7: Laser beam welding with filler material,differential transmission case (cast iron)with gear (casehardened steel)

Fig. 6: Laser induction screening of crack-free weldable materials



An innovative torsion-axial testing system to evaluate laser weldedpower train components

Task

Automotive powertrain componentsare frequently made from materialcombinations including case-hardenedand multiple alloyed steels. Advancedlaser beam welding processes areapplied to weld these material pairsusing integrated heat treatments andfiller materials resulting in crack-freeaxial or radial round seams. A typicalexample is the welding of shafts andgears. During the component’s appli-cation in the vehicle, these welds areexposed to a combination of torsionand bending loads. Currently there areno reliable fatigue strength values anddimensioning guidelines for laser beamwelding joints for components experi-encing torsion-bending loads.

Typically the weld seams do not failwhen these components are tested intransmission testing stands. Thus,while these time consuming and costlytests are indispensible for quality assur-ance, they do not provide data thatare relevant to reflect the fatiguestrength of the weld seams. Thereforeit was necessary to develop a new testsystem that directly evaluates thefatigue strength of laser-welded jointsunder conditions similar to the actual

Solution

Fraunhofer collaborated with a testingequipment manufacturer on the devel-opment and implementation of thetesting machine (grant from the Feder-al Ministry for Education and Research,02PB2073). Axial force and torquecylinders are mounted at both ends ofthe horizontal machine axis (Fig. 2).Both loading forces are decoupledusing a hydraulically mountedcrosshead. This setup is used to applyphase synchronized or phase shiftedcyclic axial and torsion loads. The sam-ple fixtures are mounted to the testaxes using cardan joints. This methodavoids additional loads caused byclamping of the welded transmissioncomponents, which naturally sufferfrom a certain degree of distorsion.

Fig. 2: Torsion-axial testing system

Fig. 1: Model test component (shaft-disk) withweld seam

loading conditions. This work includedthe development of a test component (Fig. 1) that is on the one hand similarto typical poere train components, andon the other hand makes the weldedseam its weakest joint when compo-nent failure occurs. The test machinewas to be designed to allow the inde-pendent loading with bending and tor-sion forces. The machine was alsorequired to be able to test real parts(i.e. drive shafts, tubes) in addition tothe specifically designed test compo-nents.



Fig. 5: Polished cross section through a crackedweld seam of a disk-shaft test compo-nent after torsion-axial loading

The design of the machine and theclamping system makes it possible tostudy in detail how the fatiguestrength of a weld is influenced by fac-tors such as welding distorsion, weld-ing depth, notches, filler material, stiff-ness of the seam area and the inte-grated heat treatment. The compo-nents are mounted using chuck conesystems for cylindrical shafts andthreaded flanges. The force cylinderscan apply torques as high as ±8 kNmat maximal rotation angles of ±50°. Inaxial direction forces can be applied ofup to ±40 kN at maximal displace-ments of ± 50 mm. The maximal load-ing frequency for both axes is 50 Hz.Test specimens can be sample partsand components with diameters of up to 300 mm and lengths of up to1250 mm. The acquisition of criticaltest data is performed at a frequencyof up to 10 kHz and includes torque,torsion angle, axial force, axial dis-placement and data from straingauges.

Results

After the machine was delivered to theFraunhofer IWS, its function was thor-oughly tested. The experiments aimedat evaluating the usefulness of specificmodel test component (Fig. 4). It wasdemonstrated that the design of thespecimen was indeed capable ofapplying the highest loads to thewelded joints, which leads to crack ini-tiation and failure in the weld (moltenor heat influenced zone, Fig. 5).

Additionally the test component alsopresents realistic welding conditionswith respect to welding depth andthermal conductivity. The testing com-ponents are also easy to manufactureat low costs.

The first experiments were performedapplying varying torsion and torsion-axial loading patterns. The test compo-nents were laser welded using shaftsmade from 42CrMo4 and disks madefrom 16MnCr5. Fig. 3 shows the results inform of a Woehlerdiagram. The applica-tion of the forces andtorques results instresses at the weldseam, which werecalculated as equiva-lent stresses using FEmodeling. First resultsindicate that a com-bined loading withtorsion and axialforces causes the diskto bend and thusreduces the overall fatigue strength ifcompared to pure torsion loads.

The successful implementation of theaxial-torsion test machine delivers theFraunhofer IWS with a very importanttesting capability. The system providesspecific material data that will enablethe engineering team to properly lay-out and dimension lightweight laserwelded components in particular forfuture power train components.

Fig. 3: Fatigue strength of welded disk-shafttest components

Contact

Dr. Jörg Bretschneiderphone:+49 (0) 351 2583 [email protected]

2 mm

Fig. 4: Test component, clamp flange and cardan joint of the test sys-tem during a torsion experiment


Editor: What are the new results inthe area of laser beam cutting withfiber lasers?

Dr. Morgenthal: Fundamental modefiber lasers can cut metallic materialsup to a thickness of 0.7 mm. One canexpect that the next generation ofhigher brilliance radiation sources willfurther increase the material thicknessthat can be cut. In 2008 IWS engineersused a disk laser of highest brillianceto perform cutting experiments withthick sheet metal. The results showeda similar quality and productivity ascan be achieved with a fiber laser.

Editor: Which challenges does thedepartment face with respect to devel-opments in the area of system tech-nologies?

Dr. Morgenthal: The potential ofusing remote technologies for laserprocesses such as welding, cutting,structuring, and surface treatment isby far not exhausted. These develop-ments are essentially aiming at increas-ing the processing speed by usinglasers with ever increasing beam quali-ty, power and pulse energies. Moderndisk and fiber lasers are well suited forthis task. Further development isrequired in the area of laser optics thatis integrated in the processing systemso that it can precisely deliver the laserbeam to effectively process the parts.

Editor: For many years your depart-ment has been utilizing IWS compe-tences in materials and laser technolo-gy to restore art and cultural posses-sions. What is new in this businessfield?

Dr. Morgenthal: The development ofnew laser systems, and in particularthose based on fiber lasers, lead toportable and autonomous equipmentsolutions that do not require an onsitepower outlet. These systems areexceptionally useful for field opera-tions to clean art and cultural objects.One of these developments was suc-cessfully tested to clean the burialchamber of the Nepherhotep in Egypt.However, laser technology applicationsin the area of art and cultural posses-sions are multifaceted. Since severalyears for example, we have beenworking on uncovering and analyzinghidden wall paintings, including thusfar unknown defects. Here we uselaser generated terahertz radiation. Forexample, many churches have hiddenwall paintings that have never beenrevealed. The non-destructive unveilingof the iconographic contents of theseworks of art and the investigation ofthe different stages of their making aswell as of damages promises essentialknowledge about the character andthe development of iconoclastic move-ments and their societal, religious andcultural backgrounds during variouscultural conflicts.

R&D-offer: Laser ablation and cutting, system engineering

An accepted idea turns into work.Guenter F. Gross


Dr. Lothar MorgenthalDepartment head(phone: +49 (0) 351-2583-322,[email protected])

Dr. Lothar Morgenthal Team leader system engineering(phone: +49 (0) 351-2583-322,[email protected])


Scanner optics for fiber laser HF-SAO1.06(2D)

System engineering and laser processing

New or further developed and morepowerful technologies in laser materi-als processing frequently require newsystem technologies or components inorder to optimally use them. In caseswhere this system technology is notyet commercially available, we offerthe development, testing, prototyping,and demonstration of these solutions.For example:- processing optics with enhanced

functionality, such as high speed and / or precision beam scanning forremote processing,

- control technology and CAD / CAMtools for remote and on-the-fly pro-cessing,

- system technology and software foronline process monitoring and con-trol.

Dr. Thomas Himmer Team leader cutting(phone: +49 (0) 351-2583-238, [email protected])

Cutting technology

The IWS is equipped with CO2 and solid-state lasers, and especially fiberlasers, in a wide range of powers andbeam qualities, which can be used forcutting of all materials that are used inmodern manufacturing.

Research topics include the develop-ment of technologies to optimizeprocess and cycle time. We are usinghighly dynamic 2D and 3D cuttingmachines with direct linear drives aswell as modern robots. Aside fromusing commercial processing optics wealso apply internally developed scannersystems for remote processing.

We offer:- technology and system develop-

ment, testing, and optimization,- comparison tests,- feasibility studies with prototype

manufacturing.

High speed cutting with on-the-fly nozzle system


Mobile system for the anti-slip preparation ofnatural stones

Dr. Udo KlotzbachTeam leader microprocessing (phone: +49 (0) 351-2583-252,[email protected])

Micro structuring with laser

Extensive and modern equipment aswell as our know-how foundationenable us to perform applied researchin the area of micro and fine process-ing with laser beams for the miniatur-ization of functional elements inmachine, system, and automotiveengineering as well as for biomedicalapplications. Examples are 3D struc-tures in the sub mm range and areastructures on polymers, metals, ce -ramics or quartzitic and biocompatiblematerials.

We offer:- micro structuring of different materi-

als with excimer, fiber and Nd:YAGlasers,

- micro drilling with high aspect ratiosand different bore geometries,

- cleaning with laser technology.

Examples of projects 2008

1. Selective cutting of composite materials – Highly productive andflexible due to remote cutting 42

2. Fast laser cutting with highly dynamic beam deflection optics

43

further information:www.iws.fraunhofer.de/projekte/005/e_pro005.htmlwww.iws.fraunhofer.de/projekte/036/e_pro036.htmlwww.iws.fraunhofer.de/branchen/bra06/e_bra06.html


Dr. Andrés-Fabián LasagniTeam leader surface functionalization(since Sept. 2008)(Tel. 2583 007,[email protected])

Advanced topographic design

New methods for micro/nano fabrica-tion of two and three dimensionalstructures are essential for new goalsin several areas of science and technol-ogy. The Surface Functionalizationgroup offers the possibility to fabricateadvanced architectures on polymers,metals, ceramics and coatings withmicro/nano features on macroscopicareas. In addition to topography, alsothe electrical, chemical, and / ormechanical properties can be variedlocally and periodically obtaining amacroscopic response with a betterperformance. These patterned surfacescan be used for several applications inbioengineering, photonics and tribolo-gy, between others.We offer:- design of two and three dimensional

structures on different materials, - photopolymerization, ablation and

metallurgical patterning,- high speed fabrication of high densi-

ty patterns.

Fabrication of periodic arrays on polymeric substrates for bio-applications.

5 μm



Selective cutting of composite materials – Highly productive and flexible due to remote cutting

Task

The excellent beam quality of fiberlasers holds an enormous potential toincrease the productivity of laser mate-rials processing operations. For exam-ple, the application of a fiber laserwith brilliant beam quality in combina-tion with scanner optics for beamdeflection allows the cutting of thematerial without a cutting gas. Thematerial is evaporated layer by layer. Acontour cutting speed of more than200 m min-1 is possible for thin mate-rials (Fig. 2). However, thin materials(i.e. metal foil) in particular are difficultto handle.

Contact

Dipl.-Ing. Matthias Lütkephone:

+49 (0) 351 2583 [email protected]

Fig. 2: Contour cutting speeds for fiber laser remote cutting, example geometry: hexagon

Solution

A process named "kiss cutting" mayhelp. The basis of this process is acomposite material, which consists ofthe material to be cut, and a carriermaterial. Both materials are joined butcan be separated after the cutting. Thecutting process only cuts the metallicmaterial, whereas the carrier materialremains intact. The metal film is thenremoved but the cut pieces remain onthe carrier material (Fig. 1).

Results

Remote cutting allows the selectiveseparation of the composite material.A central element is the remote cut-ting with fiber lasers. The extremelyhigh intensities evaporate the material.The evaporated material is removedupwards and not downwards as inconventional laser cutting. Thus, bycarefully selecting the laser processparameters, it is possible to only cutthe metallic film along the desiredcontour without damaging the carriermaterial.

Remote "kiss cutting" allows fast cut-ting speeds at high flexibilities. Theheat-affected zone is minimal and thecut quality is excellent. Additionaladvantages of "kiss cutting" overpunching processes include a lownoise level and a part generation with-out edge warpage.

Fig. 1: Final parts on a carrier material made by"kiss cutting"



Fast laser cutting with highly dynamic beam deflection optics

Task

Laser cutting processes are widely usedin today’s manufacturing industry.However, in particular when cuttingcontours, the high-speed cuttingpotential of the laser is in many casesnot fully utilized due to limited dynam-ics of the cutting machines. Modernfiber and disk lasers with higher bril-liance make this discrepancy evenmore obvious. This is especially evidentin the field of cutting thin and mediumthick sheet metal. Solutions are soughtthat utilize the laser beam along thecutting contour at speeds that corre-spond to its cutting capability. Simulta-neously, cutting precision and edgequality have to be maintained.

Solution

The solution to this problem is to inte-grate additional motion axes into thelaser cutting head, which take over thehighly dynamic motion of the laserbeam during phases of high accelera-tion and jerks while the main machineperforms a simplified motion path forthe laser head. The superposition ofthe motion ranges of the main (yellowin Fig. 2) and additional head axes (redin Fig. 2) allow positioning of the laserspot quickly at any desired location.An intelligent planning algorithm con-siders all conditions such as workingfield dimensions, jerks, accelerationand speed for main and additionalaxes and determines a motion paththat minimizes the cycle time.

Results

IWS engineers developed the 2D beamdeflection optics for the processinghead. This optics synchronizes the laserbeam with a separately driven cuttinggas nozzle. Nozzle and laser beammove highly dynamically close to theprocess. Splitting up the motion oflaser beam and gas jet reduces therequired weight for each additionalaxis to less than 300 g. Subsequentlythe drastically reduced inertia of theadditional axes allows accelerations of80 m s-2.

A prototype was developed to evalu-ate the system and technological limi-tations of this concept. Processing timesavings of more than 60 % weredemonstrated for complex cuttinggeometries if compared to convention-al cutting without additional axes.Simultaneously, it was also observedthat this method significantly relievedthe main machine axes.

The application of this solution makessense where sheet metalof average thickness (1 –5 mm) has to be cut intocomplex shapes at greatflexibility and high pro-ductivity. An example isthe manufacturing of sta-tor and rotor segmentsfor motors and genera-tors. Here the methodoffers an alternative tothe highly productive butinflexible stamping orflexible but slow conven-tional laser cuttingprocesses.

Contact

Dipl.-Ing. Florian Bartelsphone:+49 (0) 351 2583 [email protected]

Fig. 1: Cutting speeds as a function of materialthickness and laser type (straight cut)

Fig. 2: CAD model of the coupled axes system (yellow: main axes, red: additional axes)

Editor: For the last annual report youannounced your plan to develop newsystem technological solutions in thearea of buildup welding. What is theprogress?

Dr. Nowotny: We successfully finisheda BMBF production research programand demonstrated a CNC milling cen-ter which integrated the three-dimen-sional complete processing by applyingboth laser buildup welding and milling.In collaboration with the companyArnold, we integrated a laser process-ing head directly into the original toolholder of the milling spindle. This solu-tion provides a larger workspace, sim-plifies programming and allows for aquicker change between laser process-ing and milling.

Editor: Tell us about the laser process-ing head.

Dr. Nowotny: The system is equippedwith a well focused 1.5 kW diodelaser, which is coupled to the process-ing head via a 400 μm fiber. Coaxialnozzles deliver the welding powder.Our latest development is COAX13,which is an extremely long and narrownozzle shaped for the least possibledisturbance. This nozzle type is prefer-ably used for parts with limited acces-sibility, for example to repair turbines.

Editor: These coaxial nozzles workwith powder only, don’t they?

Dr. Nowotny: Exactly. They do havesome essential limitations even withexcellent powder utilization. Thereforewe researched the possibility of usingwires for directionally independentbuildup welding. The solution is com-prised of a new beam shaping optics,which allows the wire feed exactlythrough the center along the laserbeam axis.

Editor: What are the main topics inthermal spraying?

Dr. Berger: Decades of developmentwork in the area of spraying technolo-gy achieved a high level of technology.However, what did not change overthe last 50 years is the selection ofsprayed materials. Substantial materialsresearch is required to enable newapplications. We will be primarilyworking on the development of oxide ceramic materials based onAl2O3-Cr2O3-TiO2 as well as on hardmetals.

Editor: Does that mean that yourwork will exclusively focus on materialsdevelopment?

Dr. Berger: No. Over the past fewyears we established the technology tospray suspensions. Instead of usingpowders for APS and HVOF we areusing suspensions, which behave com-pletely different during the sprayingprocess and open up new possibilities.

Editor: What is planned in detail?

Dr. Berger: In principle we count oncoatings with multiple functions. Inparticular the material system Al2O3-Cr2O3-TiO2 offers surprising possibili-ties. For example, it is possible to gen-erate dielectric as well as electricallyconductive coatings. We intend tocombine both coating materials toform novel function coating systemsfor example of heating elements basedon sprayed coatings.

Editor: What about the hard metals?

Dr. Berger: Here we would like todevelop coatings that can be widelyused in fatigue conditions such asrolling contact applications. Untilrecently these applications were con-sidered impossible.

R&D-offer: Thermal coating


Problems are disguised opportunities.Henry Ford 1




1. Thermally sprayed hard metalcoatings for fatigue reducing rolling contact applications 48

2. Process and system technology for laser beam buildup welding in jet engine repair 49

further information:www.iws.fraunhofer.de/branchen/bra09/e_bra09.htmlwww.iws.fraunhofer.de/projekte/1-17/e_pro1-17.html



Dr. Lutz-Michael BergerTeam leader thermal spraying(phone: +49 (0) 351-2583-330,[email protected])

Wear protection and functional coatings

The IWS offers thermal spray technolo-gy development based on atmosphericplasma spraying (APS) and high velocityoxygen fuel spraying (HVOF). Powdersand suspensions are used to coat partsmade from steel, lightweight metals or other materials with metals, hardmetals and ceramics.

Based on the most modern sprayingequipment, and in cooperation withother institutes of the Fraunhofer Insti-tute Center in Dresden we offer:- conception of stress adapted coating

systems,- development of complete coating

solutions from the material to thecoated part,

- development and manufacturing ofsystem components,

- participation in system integration,- support of the user with technology

introduction.

Repair and generating

Laser beam and plasma powder cladding as well as hybrid technologiesin combination of laser, plasma, andinduction sources are available at theIWS for the repair and coating of com-ponents, moulds, and tools. Cladding,alloying or disperging of metal alloys,hard materials and ceramics can gen -erate coatings and 3D structures. Thecomplete process chain from digitizingand data preparation to the final pro-cessing can be utilized for all the tech-nologies. For these application fieldswe offer:- simulation of buildup welding

processes,- coating and shape forming laser

buildup welding at highest precision,- processing heads and CAM software

of the industrial application of lasertechnology,

- on-site support of production imple-mentations.

Dr. Steffen NowotnyTeam leader cladding(phone: +49 (0) 351-2583-241,[email protected])

TopGun® HVOF pistol in use Repair of gas turbine blades through buildupwelding with high power diode laser



Task

Conventional thermal spray coatingsare primarily used to reduce abrasive,erosive and friction/sliding wear. How-ever, modern spraying technologiessuch as high velocity oxygen fuel ther-mal spraying (HVOF) in combinationwith further developed materials havethe potential to generate protectivecoatings for parts that are exposed tohigh rolling contact loads. Good exam-ples are high performance transmis-sions.

Thermally sprayed hard metal coatings for fatigue reducing rollingcontact applications

Solution

The IWS, IKTS, LBF and IWU formed astrategic alliance of Fraunhofer insti-tutes with an industrial focus (WISA).The alliance aims at developing newsolutions to increase the performanceof thermal spray coatings so that theycan be applied in high loading applica-tions. The project considers the entiretechnology chain to understand theimportance of each processing step forthe final application performance. Theparticular IWS focus is on the develop-ment, fabrication and characterizationof thermal sprayed coatings.

Results

Preliminary experiments were per-formed to study the rolling contactperformance of casehardened16MnCr5 steel rolls, which were coat-ed with WC-17%Co. Experiments con-tinued using non-hardened 16MnCr5

Contact

Dr. Lutz-Michael Bergerphone:


Fig. 2: Microstructure of the WC-(W,Cr)2C-7%Ni coating for fatiguereducing rolling contact applications(SEM micrograph)

Fig. 1: Undamaged WC-(W,Cr)2C-7%Ni coatedsample after rolling fatigue test

steel substrates normalized to a hard-ness of HB190 and commercially avail-able coating materials WC17%Co andWC-(W,Cr)2-7%Ni. The samples wereprepared using the HVOF process todeposit two coating thicknesses with100 and 600 μm. The Hertzian contactreference stress maximum was locatedin the substrate when using a 100 μmcoating thickness and directly in thecoating at 600 μm coating thickness.The rolling contact experiments wereperformed at the Fraunhofer LBF inDarmstadt using a ZF roll test standwith a slippage of -25% and trans -mission oil SAE80 at a temperature of80 ºC in the rolling contact.

The experimental results demonstratedthe improved performance of the coat-ed rolls in comparison to the uncoatedsamples. In particular when applying600 μm of coating it was possible touse non-hardened substrate materialsto outperform casehardened butuncoated 16MnCr5 samples. Therewas no noticeable sign of wear (Fig. 1)even after 50 million rolling cycles at a Hertzian contact pressure of 2000 MPa. If the load is increased therelatively soft substrate materials leadsto failure. Therefore the continuationof this project focuses in addition toqualifying diverse coating materials onthe understanding the relationbetween substrate hardness and appli-cation performance.

100 μm



Fig. 2: Repaired edge geometry of a damagedblisk prior to the final finishing step

Task

Laser powder buildup welding is anestablished manufacturing process torepair damaged aircraft engines. Theprocessing of aerospace titanium alloyswas demonstrated in past projectssuch as AWFORS and FLEXILAS.

The objective of the work presentedhere was to repair a blisk of the firstcompressor stage of an aircraft jetengine. The blades of a blisk areexposed to sucked in debris, andtherefore face an enormous risk to getdamaged. Due to their size they arenot completely regenerated duringrepair. Instead, the worn off material isreplaced layer by layer. A special chal-lenge was the absence of any possibili-ty to mask or cool the processingregion. In addition their accessibilitywas limited.

Process and system technology for laser beam buildup welding injet engine repair

Solution

As a first step IWS engineers collabo-rated with MTU Aero Engines GmbHto perform extensive investigations onregenerating the desired geometry.These experiments were part of anextension to the BMBF project FLEXILAS.

In particular when generating the firstlayers, heat gets trapped which meltsthe blade and can easily lead to thedestruction of the entire part. A prop-er processing regime was developed ina series of welding experiments. Thereproducibility of fabricating thedesired geometry was demonstrated(Fig. 2).

Contact

Dipl.-Ing. Robert Münsterphone:+49 (0) 351 2583 [email protected]

Fig. 3: Polished cross-section of the addedstructure. The individual layers are recognizable as well as the several layerspanning broad range structure

Fig. 1: COAX13 powder nozzle

Results

As anticipated, the pore free charac-teristic material structure was repro-duced layer by layer. The structure isdense and fine crystalline. A broaderscale structure is formed due to epitax-ial crystalgrowthbetweenwelding layers (Fig. 3).

The results also showed limitations inaccessing the regions which have tobe repaired. The blisk geometry iscomplicated and conventional powderdelivery nozzles could not reach farenough. Therefore the COAXn familyof nozzles was expanded. TheCOAX13 nozzle is very long and nar-row (Fig. 1). This 300 mm long and 31 mm diameter nozzle can be usedto repair blisks with blade distances ofless than 20 mm. The powder is notdelivered through a ring shaped gap.Instead, a specially designed set ofpowder/gas channels feeds the pow-der to the processing region.

Currently the regenerated blades arebeing tested for vibration performanceat the customer.

The process was performed in anargon atmosphere to avoid oxidationof the repaired blades. The lasersource was a 4.4 kW solid state laser.

5 mm


Editor: Your department developsCVD processes for large area applica-tions. What are the key challenges?

Prof. Kaskel: New thin film technolo-gy solutions benefit from a paralleldevelopment of processes andmachine technology. Particular chal-lenges and solutions we see are in thearea of the photovoltaic industry forwhich we develop processes and sys-tems. The department focuses onchemical vapor deposition at atmos-pheric pressure. Here we see theopportunity to support the solar cellmanufacturing industry, which is fac-ing an ever increasing cost pressure.This is true for the manufacturing ofcrystalline as well as thin film solarcells. The advantage is self-evident.Complex vacuum system technology isexpensive and requires a large foot-print whereas compact atmosphericpressure processing heads can be easi-ly moved toward the part to be coatedand allow a continuous processing setup.

Editor: What are the new results inthis application area of photovoltaics?

Prof. Kaskel: In 2008 we managed tosignificantly improve our in-housedeveloped arc technology. Today wecan homogeneously coat a width of25 cm in pass-through inline reactors.Next year we will further incrementthe width to continuously coat 60 cmwide parts.

For the manufacturing of solar cells we developed a continuous plasmaetching process, which leads to anincreased efficiency of the cells. Ourantireflective coating increases thelight absorption. In comparison to con-ventional processes, our new technolo-gy does not require vacuum makingpossible a continuous processing.

CVD methods at atmospheric pressureare also advantageous in thin filmphotovoltaics. Here we developed in2008 processes to deposit transparentconductive oxides, which are the basisof thin film solar cells.

Editor: How important is processmonitoring for the development work?

Prof. Kaskel: Our processes wouldonly be half as efficient if we wouldnot use the most modern inline moni-toring methods. These include, forexample, laser diode spectroscopy todetect trace amounts of water inprocesses. Using these methods allowsus to optimize the utilization of pre-cursors. The monitoring also enablesprocess control methods to makethem safe and environmentally sensi-tive by eliminating the emission of poi-sonous substances, for example. In2008 we significantly expanded in thisarea. It turned out that the developedmonitoring techniques proved to beexcellent control tools for manufactur-ing processes in the chemical industry.The spectrum spanned from simpledrying processes to the fabrication ofnanoparticles.

R&D-offer: CVD thin film technology

New challenges present wonderful opportunities to discover more about oneself.

Ernst Ferstl


Prof. Stefan KaskelDepartment head (phone: +49 (0) 351-2583-331,[email protected])



1. Transparent conductive oxide (TCO) for solar cells 54

2. Atmospheric pressure plasmas for large area applications in photovoltaics 55

further information:www.iws.fraunhofer.de/projekte/1-27/e_pro1-27.htmlwww.iws.fraunhofer.de/projekte/1-28/e_pro1-28.html



Dr. Ines Dani Team leader atmospheric pressure CVD (phone: +49 (0) 351-2583-405,[email protected])

Dr. Wulf Grählert Team leader process monitoring (phone: +49 (0) 351-2583-406,[email protected])

FTIR monitoring of high temperature processesView of the coating area of the ArcJet-PECVDsystem

Plasma enhanced CVD processes atatmospheric pressure

Plasma enhanced chemical vapordeposition processes at atmosphericpressure produce large area and high quality functional coatings without theneed for costly vacuum systems. Theprocesses can continuously coat athigh deposition rates on temperaturesensitive (i.e. special steels, lightweightmetals, glasses and plastics) flat as wellas slightly curved materials. At theFraunhofer IWS we develop prototypeinline reactors for the synthesis ofoxide and non-oxide coatings as wellas plasma chemical etching processesat atmospheric pressure. The optimiza-tion of the reactor design is based onexperimental results and thermo-fluiddynamic simulations. The modularreactor design promotes a cost effi-cient adaptation of the processes tonew applications and coating materi-als.

Process monitoring

In many cases the optimal function ofindustrial equipment and the quality ofthe manufactured products dependdirectly on the gas atmosphere insidethe system. Therefore its compositionhas to be monitored at tight tolerancelevels. An industry compatible gas ana-lytics is essential for the quality controlof chemical deposition, etching, andsintering processes and for monitoringthe emissions of industrial machines.For customer specific solutions to con-tinuously monitor the chemical com-position of gas mixtures, IWS is usingsensors that are alternatively based oneither NIR diode laser or FTIR spectro -scopy.

Furthermore we analyze surfaces andcoating systems with spectroscopicmethods such as FTIR spectroscopy,spectro-ellipsometry or Raman microscopy.

Dr. Holger Althues Team leader chem. surface technology (phone: +49 (0) 351-2583-476,[email protected])

Hydrophilic / hydrophobic structured surface ona stainless steel sheet

Chemical surface technology

Engineered material surface propertiesand functions vary widely dependingon the application. The requirements,for example, include corrosion andscratch protection, anti-fingerprint orself-cleaning functions, optical trans-parency and electrical conductivity. Inaddition, surfaces of functional ele-ments such as electronic componentsmay have to perform very specializedfunctions. All the properties can beengineered by applying special func-tional coatings or surface treatmentprocesses. This step requires costeffective and often large area process-es. The chemical surface technologiesgroup at IWS develops chemical vapordeposition (CVD) and wet chemicalprocesses and combines them to gen-erate a diverse range of surface func-tionality on various substrates.



Transparent conductive oxide (TCO) for solar cells

Task

Transparent conductive oxides (TCO)have many applications including heatable glazing and transparent electrodes for displays and solar cells.

Fluorine doped tin dioxide (SnO2:F,FTO) presents a cost effective alterna-tive to the commonly used tin dopedindium oxide (In2O3:Sn, ITO). For thinfilm photovoltaic applications thesefilms have to be highly transparentand conductive. In addition theyrequire a well-defined surface struc-ture to efficiently couple the light viascattering effects (Fig. 1).

Solution

At the Fraunhofer IWS, engineers andscientists develop chemical vapordeposition processes that operate atatmospheric pressure (AP-CVD, Fig. 2).These processes allow the large areaand continuous treatment of sub-

strates withoutthe need for cost-ly vacuum sys-tems. AP-CVDcan deposit vari-ous metal oxidesincluding SnO2:Fat medium temperatures (< 400 ºC) ontomany tempera-ture sensitive sub-strate materials

such as heat treatable steels, alu-minum or preformed glass. The coat-ings are homogeneous, conform andadhere well with thicknesses up to1000 nm.

Fig. 1: Schematic design of a thin film solar cell

Results

The AP-CVD process was used todeposit FTO at deposition tempera-tures between 200 - 350 ºC onto several substrates. The deposited filmswere then analyzed with respect totheir optical, structural and electricalproperties.

Coated glasses show a high diffusetransmission exceeding 85 % in thevisible spectrum. X-ray diffractometryanalysis revealed a crystalline rutilestructure. AFM imaging demonstratedthe synthesis of smooth as well as tex-tured coatings. The produced surfaceroughnesses ranged from Ra = 7 nmto Ra = 40 nm. The sheet resistancewas measured using a four-pointprobe method yielding only 10 Ω / □.The specific resistance was measuredat 10-3 Ω cm. The FTO coating com-bines properties such as transparency,electrical conductivity and adjustablesurface texture. They have a greatpotential as electrode material for photovoltaic and illumination applica-tions. The AP-CVD process is in par -ticular useful for the coating of largearea substrates at temperatures of < 400 ºC.

Contact

Dipl.-Ing. Thomas Abendrothphone:


Fig. 2: Mobile AP-CVD processing head for the deposition on substrates of up to300 x 300 mm2



Atmospheric pressure plasmas for large area applications in photovoltaics

Task

Continuous fabrication processesbecome increasingly important in solarcell manufacturing due to theirimproved material flow and reducedwafer breakage. The overall manufac-turing process can be substantially simplified by introducing inline plasmatechnologies for etching and deposi-tion steps and the transition from vacuum to atmospheric pressure oper-ation. The challenge is to develop larger area plasma sources and passthrough reactors for the operation atatmospheric pressure.

Solution

Two complementary atmospheric pres-sure plasma sources are used toprocess 156 x 156 mm2 wafers. Onesource is a linear direct current arc dis-charge (Fig. 2) and the other is amicrowave plasma generator. Anargon / nitrogen gas mixture streamsthrough the plasma sources. The excit-ed species leave the plasma sourceand flow toward the substrate. Therethe reactive precursors are added toperform either etching or depositionreactions.

Fig. 1: Schematic representation of the produc-tion flow to fabricate solar cells, theboxes marked in green are processingsteps that were researched at the IWS

Etching chemistries, that are typicallyused in the semiconductor industry,are also here applied to etch silicon.Typical gases are NF3 and SF6. Siliconnitride is deposited to form passivatingand antireflective layers. The precur-sors are silane or a metal organic pre-cursor and ammonia. The engineeringof the flow dynamics in the plasmasources and the reactor is based onfluid dynamic simulations (Fig. 3).

Fig. 4: Schematic representation of an atmospheric pressure reactor for plasma chemical etching

Fig. 3: Fluid dynamic simulation of layer depo-sition within the reaction zone

Fig. 2: Direct current arc discharge plasmasource with a working width of 250 mm

5 · 10-5

4 · 10-5

3 · 10-5

2 · 10-5

1 · 10-5

Contact

Dr. Gerrit Mäderphone:+49 (0) 351 2583 [email protected]

Results

All process steps marked in green inFig. 1 have been successfully demon-strated in the laboratory. The IWSprocess for edge isolation has alsobeen successfully tested in severalindustrial experiments. During thesetests the wafers were processed withindustrial standard processes onsite atthe customer facility. Only the edgeisolation step was performed at theFraunhofer IWS. The backside and theedges of the wafers were plasmachemically etched using NF3 achievingetching rates in the order of 3.7 μm m min-1. The so plasmaprocessed wafers showed an increasedefficiency of 1.6 % (rel.) if comparedto wafers that were conventionallyedge isolated.

Editor: The employees in your depart-ment are working on various aspectsand applications of PVD thin film tech-nology. What special progress wasmade in 2008?

Dr. Leson: In the area of classic hardcoatings we worked on very thick lay-ers exceeding 50 μm. Normally suchthick layers tend to be inhomogeneousand flake off the substrate. By apply-ing a special coating design, we man-aged to overcome these conventionallimitations. We are now able todeposit very thick, smooth and adher-ing coatings, which can be mechani-cally post processed. Interesting appli-cations are envisioned in the area offabricating long lasting machine com-ponents and tools.

In the field of carbon coatings we con-tinue to focus on our Diamor® films.Their outstanding properties such asthe very high hardness and extremelylow friction coefficients provide greatpotential for the automotive industry.Last year we optimized the reliabilityof Diamor® coating systems forextremely high loading conditions. Inconjunction with the associated depo-sition machine technology, the coat-ings are ready for industrial applica-tions.

Editor: Your department is also work-ing on the fabrication of single wallcarbon nanotubes. How is yourapproach different from the many other groups working on this topic?

Dr. Leson: We developed a process to produce larger quantities of singlewall carbon nanotubes of high quality.Other groups and manufacturers focuson the simpler manufacturing of multiwall carbon nanotubes. This providesus with a unique selling proposition,because the exceptional propertiesthat are expected of carbon nanotubescan only be achieved with the singlewall version.

Editor: Aside from the establishedareas you also picked up new subjects.

Dr. Leson: A very interesting recenttopic is the development of reactivemultilayers. These are nanometer filmstacks of two different materials,which can rapidly release energy whena chemical reaction between them isinitiated. The amount of released ener-gy is precisely adjustable by changingthe materials and film thicknesses. Thereaction and energy release timing canalso be adjusted. In combination withsoldering foils it is possible to joincomponents with very high accuracy.The heat is released directly in theregion were the materials are joined,which keeps the overall thermal loadon the component very low. This qual-ifies the process especially as a microjoining technology. But we are alsolooking at other applications for whichwe developed different reactive multi-layers. This work clearly benefits fromour experience and know-how indeveloping multilayer thin films forEUC and X-ray optical applications.

R&D-offer: PVD- and Nanotechnology


Ideas won’t keep; something must be done about them.

Alfred North Whitehead


Dr. Stefan Braun Team leader X-ray and EUV optics(phone: +49 (0) 351-2583-432,[email protected])

Dr. Andreas LesonDepartment head(phone: +49 (0) 351-2583-317,[email protected])


Mirrors with reflective coating

Fabrication and characterization ofnanometer precision coatings

Nanometer single layer and multilayercoatings are used in EUV and X-rayoptics for beam shaping and mono-chromator applications. For the depo-sition of metallic and dielectric coat-ings we use magnetron and ion beamsputter deposition as well as pulselaser deposition. The coating systemsare characterized by:- highest thickness precision,- smallest roughness,- high chemical purity,- excellent lateral homogeneity,- very good reproducibility.

In addition to the development andfabrications of precision coatings, weare offering our long-term experiencein characterizing and modeling ofnanometer coatings. The followingtechnologies are available in our laboratory:- X-ray reflectometry,- EUV reflectometry,- X-ray diffractometry,- residual stress measurements.

Carbon nanotubes

Carbon nanotubes show a number ofinteresting properties such as highstrength, very good thermal and elec-trical conductivity, and interesting opti-cal properties. Only small quantities ofcarbon nanotubes added to compositematerials can open completely newfunctionalities for the matrix materialwhile simultaneously maintaining theconventional matrix properties andkeeping established production linesunchanged.

At Fraunhofer IWS we developed anovel process for the synthesis of high-quality single wall carbon nanotubeswith a very narrow property spectrum.We are currently up-scaling theprocess. For the development of com-posite materials with special propertieswe are offering carbon nano tubes indifferent qualities and processingstages. The development of compositematerials can be supported by model-ing and extensive characterization.

Arc synthesis of filaments made of carbon nanotubes

Dr. Oliver Jost Team leader carbon nanotubes(phone: +49 (0) 351-2583-477, [email protected])




1. Hard coatings > 20 μm – new possibilities for thin film technology 60

2. Optimization of high perfor-mance ta-C coatings systems 61

3. Nanometer reactive multilayers as precisely controllable energy storage devices 62

4. Ion beam processing of optical surfaces 63

Coating with super hard amor-phous carbon

Amorphous carbon coatings withtetrahedral diamond bonds (ta-C)combine high hardness, low friction,and chemical inertness. Therefore theyare exceptionally useful as protectivecoatings. The IWS developed ta-Ccoating systems (Diamor®) can bedeposited with excellent adhesion inthe thickness range from a fewnanometers up to several tens ofmicrometers. The deposition occurs atlow temperatures in vacuum through aspecial developed pulsed arc process.For the commercialization of Diamor®

coatings the IWS delivers jointly withpartners the technology as well as thenecessary deposition sources and coat-ing equipment. The offer also includesthe laser acoustic quality control andprocess optimization equipmentLAwave®.

Dr. Otmar Zimmer Team leader PVD coatings(phone: +49 (0) 351-2583-257,[email protected])

Metal evaporation through electron beam tech-nology

Coating through activated highrate processes

Processes involving the physical depo-sition from the vapor phase (PVD =physical vapor deposition) allow forthe deposition of high quality tribolog-ical and functional coatings in thethickness range from a few nanome-ters to several tens of micrometers. Atthe IWS, we have a number of tech-nologies at our disposal from high rateevaporation to highly activated plasmaprocesses and their combinations. Aspecial focus is the extensive utilizationof arc discharges, which are the mosteffective source of energy rich vaporjets. Based on these technologies weoffer:- sample coatings,- coating characterization,- development of coating systems,- customer specific adaptation of coat-

ing technologies,- feasibility and cost studies,- development and manufacturing of

adapted equipment components.

Equipment for the deposition of super hardamorphous diamond-like carbon coatings(Diamor®) based on the Laser-Arc process

Dr. Volker Weihnacht Team leader carbon coatings (phone: +49 (0) 351-2583-247,[email protected])

further information:www.iws.fraunhofer.de/branchen/bra07/e_bra07.htmlwww.iws.fraunhofer.de/projekte/1-22/e_pro1-22.html



Hard coatings > 20 μm – new possibilities for thin film technology

Task

PVD (physical vapor deposition)deposited classic hard coatings such asnitrides, oxides and carbon films aretypically thinner than 10 μm. However,special applications could greatly bene-fit from hard coatings thicker than 20 μm. For example, machine compo-nents and tools could experience adrastically increased service life. Anincreased coating thickness also offersthe possibility to post process the ma -terial and to structure it, for example.

Thick coatings often tend to delami-nate or form cracks due to residualstresses in the film. Also, the coatingprocess becomes more and more timeconsuming with increasing thicknessand the deposited coatings turnincreasingly inhomogeneous. The rea-son for the latter is the formation oflarger growth defects in the coatingthroughout the process.

Solution

The key to produce thick coatings withPVD methods lies therefore in effec-tively preventing the growth of exist-ing defects (e.g. particle deposited onthe substrate during vacuum arc depo-sition, the PVD process used for thehere presented results). Another factoris to embed the defects into the coat-ing structure without destroying it. The initial thought was that thegrowth of defects could only be inter-rupted if the original defect is covered

Results

Using the nanolayer architecture it waspossible to deposit 60 μm thick coat-ings. An important goal is the possibili-ty to mechanically process the coat-ings; for example by grinding. This wasdemonstrated on thickly coated testspecimen made from hard metal. Asample was ground to show the tran-sition from the hard metal substrate tothe coating, which allows the compari-son of both (Fig. 3). The edge in thecoating material is clearly smootherand more homogeneous than the hardmetal. There are no coating damages(i.e. spalling) or defects visible. Andthe coating is substantially harder thanthe hard metal.

Fig. 2: Homogeneous coating structure due toindividual layer thicknesses of only a fewnanometers (CrN/TiN)

Fig. 3: Ground edge of a coated test specimen

with a layer from a different material.This layer should prevent the furthergrowth of the defect’s microstructure.Therefore a multilayer structure is use-ful for suppressing defect growth.Investigations with various multilayercoatings demonstrated that it is possi-ble to stop the growth of existingdefects and to further build up thecoating to become flatter and morehomogeneous while completelyembedding the defect (Fig. 1). Thecoatings can be further improved byreducing the thickness of the indi -vidual layers to the nanometer range(nanolayers, Fig. 2).

Contact

Dr. Otmar Zimmerphone:


Fig. 1: Successful embedding of growth defectsby subsequently deposited CrN/TiN mul-tilayers

1 μm

3 μm

3 μm



Fig. 2: Schematic design of the threshold loadtribometer to characterize the load per-formance of coatings under lubricatedconditions

Task

Diamond-like carbon coatings (DLC)are known for a unique combinationof high wear resistance and low fric-tion properties. They are used in indus-trial applications for numerous toolsand sliding components. However, stillproblematic for many applications arethe high compressive stresses and thelow plasticity of the coatings. Thecompressive stresses and low plasticityreduce the dynamic loading capacityof the coatings and can lead to failuressuch as spalling. IWS engineers aretherefore developing DLC coatingsespecially for high load bearing appli-cations such as gears.

Solution

So far metal doping has been theapproach for a-C:H coatings, whichincreases the toughness but alsoincreases friction and reduces wearresistance. Another solution was todesign coating stacks with additionalsupport layers, which means additionaleffort and costs.

The IWS developed ta-C coatings inorder to increase the stability underhigh loads. The development aims atmultilayer structures made from softergraphitic as well as hard diamond-likecoatings. The optimization of thesecoating stacks is supported by numeri-cal simulation of critical stresses in thecoating-substrate compound. Based ona given loading profile the simulationdetermines for different coating archi-tectures the stress distributions. Thus,it is possible to identify those coatingdesigns that minimize the criticalstresses for the given application.

Results

Initial 2.5μm thick ta-C and a-C coat-ings were produced from a graphitecathode using a pulsed arc process.Coatings with varying fractions of dia-mond bonds are produced by differentprocess parameters. As a result the E-modulus of the coatings can be adjust-ed between 180 and 430 GPa. Corre-sponding with the E-modulus the com-pressive stresses can be reduced from3 GPa to 0.2 GPa.

The measured E-modulus and residualstress values provided input for thesimulation of the elastic contact load-ing to determine an optimal sequenceof soft and hard layers. The calculatedlayer sequence was then produced onsteel samples to test their fatigueresisting performance. These testswere performed using an especiallydeveloped threshold load tribometer.The machine applies a complex load-ing pattern consisting of dynamic com-pression and oscillating sliding (Fig. 2).

At a given average compressive loadthe samples wereexposed to oscillatingfretting until signifi-cant coating failureoccurred. Fig. 1 plotsthe resulting data foran optimized ta-C/a-Cmultilayer in compa -rison to a standard ta-C film in aWoehler diagram. Asindicated by the plotthe optimized coating has a 100-foldincreased load performance. Theseoptimized coating architectures are forexample applied on high performancegears.

Optimization of high performance ta-C coatings systems

Fig. 1: Mechanical strength of two coatingtypes measured in the threshold load tribometer (Woehler diagram)

Contact

Dr. Volker Weihnachtphone:+49 (0) 351 2583 [email protected]

Fig. 3: A gear coated with an optimized ta-C/a-C multilayer coating



Task

Numerous industrial processes requirea very well defined and quick releaseof energy. For example, when joining

temperature sensitivematerials, it is neces-sary to apply therequired temperatureonly very briefly toavoid damaging thecomponents and ther-mal warpage.

Nanometer reactive multilayers as precisely controllable energy storage devices

Solution

Nanometer multilayers offer anextremely precise opportunity to storeand release energy. These multilayersconsist of different materials thatrelease energy when chemically react-ing with each other. The multilayerdesign allows to very accurately adjustthe amount of stored energy and thusto tailor the process to specific applica-tions. Since 2007, engineers at theFraunhofer IWS in Dresden have beenworking on the development of thesereactive multilayer coatings (RMC) inaddition to developing high precisionnanometer multilayers for X-ray andEUV optical applications. The RMCsconsist of several hundreds, up tothousands, of 10 – 100 nm thick indi-vidual layers of at least two differentmaterials, which react exothermallywith each other (Fig. 1).

Physical vapor deposition technologiessuch as magnetron sputtering and ionbeam sputtering are applied to fabri-cate RMCs with total thicknesses of upto 100 μm. The RMCs are depositeddirectly onto the component or fabri-cated as a freestanding foil, whichmakes it very flexible for various appli-cations.

Results

Tailoring the design of the RMC allowsadjusting the propagation velocity ofthe reaction front, the amount ofreleased heat and the maximum tem-perature. It is possible to achieve local-ized temperatures of up to 2000 ºCand propagation velocities from 2 – 20 m s-1. IWS engineers are work-ing on improving the performance ofalready known material systems suchas Ni/Al and Ti/Al. They are alsoresearching alternative material sys-tems to develop a wide range of ener-gies and to explore new applicationfields for RMCs such as brazing. Spe-cial emphasis is also placed upon thescaling of the technology to large areaand freestanding reactive foils (Fig. 3).Fig. 3: Freestanding Ni/Al reactive multilayer

coating, thickness 25 μm, diameter 50 mm

Fig. 2: Electrical ignition of a reactive multilayercoating

Fig. 1: Schematic design and principle of reactive multilayer coatings

Contact

Dipl.-Ing. Georg Dietrichphone:


Each RMC stores a defined amount ofenergy, which can be used as a local-ized source of heat. The RMC is ignit-ed by an external energy source suchas an electric spark (Fig. 2) or a laserpulse. As a result of the ignition thematerials of the individual layers inter-diffuse and undergo a chemical reac-tion while releasing energy. The reac-tion zone subsequently propagatesand so does the heat front. In a veryshort time the stored energy isreleased into a narrow region. Usingthis heat source to fabricate solderedjoints minimizes the heat and stressintroduction to the adjacent compo-nents. The heat is released exactly atthe location where it is needed toform the joint.



Task

The shaping, smoothing and coatingof optical surface requires highlysophisticated processing techniques.Important parameters are the accuracyof the contour as well as the surfaceroughness. Both are particularly diffi-cult to manage for X-ray optical com-ponents. Typical X-ray mirrors forexample have a 2-dimensionally curvedaspherical contour, which is mostlyfabricated from flat or spherical sub-strates (silicon or quartz glass). Therequired micro roughness of the mirrorsurface as well as the coatings is in theorder of 0.1 nm to achieve sufficientreflectance.

Ion beam processing of optical surfaces

Results

Fig. 1 shows the 1-dimensional con-tour profile of a curved (R = 10 m)quartz glass mirror prior to and afterion beam processing. It can be seenthat the final contour matches the the-oretical elliptical curve. The data wereobtained by laser triangulation. Themeasurements allow to estimate a figure slope error of ΔΘ < 0.01° (0.2 mrad) in comparison to the targetgeometry. This error is approximatelyequal to the half width of thereflectance maximum (1st Bragg peak)of the subsequently deposited multi-layer coating.

Fig. 2 shows AFM images of the initialand final roughness-es of the quartz glasssurface. Across the20 x 20 μm2 AFMscanning area themicro roughness isreduced from 0.73 nm to 0.26 nm.Fig. 3 shows exam-ples of X-ray opticalcomponent whichwere processed inthe "IonSys 1600"machine.

Fig. 2: AFM images (20 x 20 μm2) prior to(upper) and after (lower) ion beam pro-cessing

Fig. 1: Surface profiles of an elliptical X-ray mir-ror prior to and after processing in the"IonSys" machine

can be completely avoided, which pro-tects the surface. Each processing steprequires specific energies and rates.Both ECR ion sources can be adjustedto stable energies between 50 and2000 eV. The system is designed withlinear ion source. It is possible tohomogenously and reproducibly treat large area substrates of up to500 x 200 mm2.

Contact

Dipl.-Phys. Peter Gawlitzaphone:+49 (0) 351 2583 [email protected]

Solution

Ion beams are a well-defined andreproducible tool to process solid statematter. Simultaneously they do notpenetrate deeply into the material.Thus they represent an ideal tool toprocess optical surfaces. They can beused to shape the contour of a com-ponent and to polish and clean its sur-face by removing material. Ion beamsare also used to deposit layers ontothe optical surfaces.

The ion beam sputtering machine"IonSys 1600" is capable of perform-ing all the mentioned processes to fab-ricate (X-ray) optical components. Theprocessing can be done in one systemsince the machine has a primary ionbeam to sputter the coating materialand a secondary assisting ion beam,which can be directed toward the sub-strate itself. Intermediate venting ofthe chamber between process steps

Fig. 3: Examples of 1- and 2-dimensionally curved X-ray mirrors prior toand after ion beam processing and coating


Names, dates, events

Special Events

January 31st, 2008Colloquium "New materials, innovativeprocesses and their applications" inhonor of the 63rd birthday of Dr. habil.Volkmar Hopfe

February 12th - 13th, 2008TAW symposium "Thermal coatingwith laser based manufacturingprocesses" , held by the TechnicalAcademy Wuppertal e.V. in collabora-tion with the Fraunhofer IWS and theRofin Sinar GmbH in Dresden

March 10th, 2008"Young talent forum" event during the"Nanofair 2008"(organizer: Fraunhofer IWS Dresden)

March 11th - 12th, 20086th International nanotechnology sym-posium "Nanofair – New ideas forindustry" at the International CongressCenter in Dresden (co-organizer:Fraunhofer IWS Dresden)

March 13th, 2008"Nanotechnologies for energy andenergy efficiency" – Special event dur-ing the "Nanofair 2008" (organizer:Fraunhofer IWS Dresden)

April 17th, 2008"Aerospace Day", held by the FederalAssociation of the German AerospaceIndustry (BDLI) e.v. and the AerospaceTechnology Competence Center Saxony / Thuringia e.V. at the Fraunhofer IWS Dresden

April 22nd - 23rd, 2008Workshop "Laser systems & photo-voltaics", held by the Carl-Hanser pub-lishing house in Fellbach near Stuttgart(co-organizer: Fraunhofer IWS Dres-den)

April 24th, 2008Fraunhofer institutes center participa-tion in the nationwide "Girls Day"

May 16th, 20084th meeting of former colleagues andalumni of the Fraunhofer IWS Dresdenand the University of Technology Dres-den department LOT

June 24th - 25th, 20087th workshop "Industrial applicationsof high power diode lasers" at theFraunhofer IWS Dresden

July 4th, 2008Fraunhofer Institutes Center participa-tion in the "Long Night of theSciences" in the state capital, Dresden

Saxony’s Minister President Prof. Georg Milbradt participated in the "Aerospace Day" of the BDLI e.V.(April 17th, 2008)



Mr. Andreas Wessel-Terharn (Federal Ministryfor Transportation) opens the 7th workshop"Industrial Applications of High Power DiodeLaser" (June 24th - 25th, 2008)

Long Night of the Sciences at the FraunhoferIWS Dresden (July 4th, 2008)

July 25th, 2008"Technology Day" in Bozen (Italy) – Anevent held by the Steibneis TechnologyGroup and the TIS Innovation ParkBozen. The Fraunhofer IWS signs acontract with 8 additional Europeanpartners to collaborate in the area oftechnology and knowledge transfer,education and continuing education aswell as the exchange of experts.

September 24th, 2008Ceremonial opening of the "Fraun-hofer Project Center for IntegratedManufacturing" at the Technical Uni-versity Wroclaw. Federal ChancellorDr. Angela Merkel participated andwas granted an honorary doctorate bythe TU Wroclaw.

October 14th, 2008DPS customer day 2008 "Fascination4D" at the Fraunhofer IWS Dresden

October 17th, 2008Workshop "Surface technology in pro-duction – coatings in lubricated andnon-lubricated systems", held by thejournal "Metal Surface" and the Fraunhofer IWS Dresden

October 27th, 20082nd German-British Nanoforum "Com-mercializing Future Technologies forEnergy and Automotive Applications"in London (co-organizer: FraunhoferIWS Dresden)

November 5th - 6th, 20084th International workshop "FiberLaser" at the International CongressCenter in Dresden (organizer: Fraunhofer IWS Dresdenand Fraunhofer IOF Jena)

November 12th - 13th, 2008Status seminar "Industry meets sci-ences", held by the project sponsorJuelich at the Fraunhofer IWS Dresden(organizer of the seminar: FraunhoferIWS Dresden)

November 27th - 28th, 2008Workshop "Laboratory sources forshort wavelengths", held by the Euro-pean Cooperation in the Field of Sci-entific and Technical Research (COST)at the Fraunhofer IWS Dresden (organizers: AXO Dresden GmbH andFraunhofer IWS Dresden)

Surface Engineering und Nanotech-nologie (SENT)

The Fraunhofer IWS in collaborationwith Fraunhofer Technology Academyand the TU Dresden launched a seriesof continuing education coursesaddressing industrial thin film technol-ogy. These courses are offered as gen-eral lectures at the IWS and as specialon-site packages for industrial cus-tomers.

October 18th - 20th, 2008"Optical thin film systems"

November 4th,6th,11th,13th, 2008"Processes to deposit thin films"

Three-dimensional presentation of the InFoCarduring the Long Night of the Sciences (July 4th,2008)


Committees

Dr. L.-M.Berger:Association of Thermal Sprayers e.V.(GTS) e.V.

Dr. L.-M.Berger:European Powder Metallurgy Association

Prof. E. Beyer: Member of the Executive Committeeof the Fraunhofer-Gesellschaft

Prof. E. Beyer: Chairman of the Fraunhofer SurfaceTechnology and Photonics AllianceVOP

Prof. E. Beyer: Director of the Institute for Surfaceand Manufacturing Technology IOF(TU Dresden)

Prof. E. Beyer: Chairman of the work group "Engi-neering Sciences" as well as memberof the board of the scientific societyfor laser technology WLT e.V.

Prof. E. Beyer:Member of the Materials ResearchAssociation Dresden e.V.

Prof. E. Beyer:Member of the Dresden discussionforum of economy and science

Prof. E. Beyer:Member of the Sachsenberg-Gesellschaft e.V.

Prof. E. Beyer:Member of the Federal Association ofMedium-sized Industries e.V.

Prof. E. Beyer:Member of the European ResearchSociety "Thin Films" e.V. (EFDS)

Prof. E. Beyer:Member of the competence center"Aerospace Technology Saxony /Thuringia e.V."

Prof. E. Beyer:Member of the University Center forAerospace (UZLR) of the TU Dresden

Prof. E. Beyer:Member of the advisory board of theEuropean Laser Institute (ELI)

Prof. E. Beyer:Member of the review committee ofthe AiF

Prof. E. Beyer:Member of the board of directors ofthe Laser Institute of America (LIA)

Prof. E. Beyer:Member of the board of stakeholdersof the Technology Platform Photonics21

Prof. E. Beyer:Member of the Society for ChemicalTechnology and Biotechnology e.V.(DECHEMA)

Prof. E. Beyer:Member of the international advisoryboard of the Journal of Laser Applica-tions (JLA)

Prof. B. Brenner: Technical committee 9 of the AWT

Prof. B. Brenner:Member of the review committee ofthe AiF

Dr. I. Jansen:Member of the Society for ChemicalTechnology and Biotechnology e.V.(DECHEMA)

Dr. I. Jansen:Member of the industrial task force"Intlaskleb" of the BMBF




Dr. R. Jäckel: Working committee "Fairs and PublicRelations" of the Materials ResearchAssociation, Dresden

Dr. G. Kirchhoff: Working committee "Acoustic Emis -sion Analysis" of the DGzfP

A. Kluge: Speaker for the computer operators ofthe Fraunhofer-Gesellschaft

Dr. A. Leson: Member of the Advisory Board of themagazine "NanoS"

Dr. A. Leson: Speaker for the nanotechnology com-petence center "Ultrathin FunctionalFilms"

Dr. A. Leson: Committee member of the magazine"Vacuum and Research in Practice"

Dr. A. Leson: Member of the International ExpertPanel for the Nanomat-Program ofNorway

Dr. A. Leson: Board member of the working groupof nanotechnology competence cen-ters in Germany

Dr. A. Leson:Member of the advisory council of theVDI

Dr. A. Leson:Chairman of the VDI working circle"Study Programs in Nanotechnology"

Dr. A. Leson:Member of the program committee ofthe VDI scientific advisory board

Dr. A. Leson:Member of the international advisoryboard of the journal "Micromaterialsand Nanomaterials"

Dr. A. Leson:Member of the Board of the EuropeanCenter for Micro and Nano Reliabilitye.V.

Dr. A. Leson: Member of the board of directors ofthe European Research Society "ThinFilms" e.V. (EFDS)

Dr. A. Leson, Dr. H.-J. Scheibe, Prof. B. Schultrich: Task force plasma surface technologiesof the DGO

Dr. S. Nowotny: DVS working committee V9.2 / AA 15.2 "Laser Beam Weldingand Related Techniques"

Dr. B. Winderlich: Work group "Stability and Construc-tion" of the DVS-BV Dresden



IWS prizes in 2008

1. Best innovative product idea

Jan Hannweber, Stefan Kühn, Michael Melde, Sven Bretschneider"Traps - eine neuartige Laserschutz-wand" "Traps – a novel laser safety wall"

2. Best scientific technical performance

Michael Leonhardt, Dr. Carl-Friedrich Meyer"Modifizierung der Ionenkinetik zurOptimierung der mittels Laser-Arc-Modul (LAM) abgeschiedenen Koh-lenstoffschichten auf 3D-Maschi-nenkomponenten""Modification of the ion kinetics tooptimize Laser-Arc-Module deposi-ted carbon coatings for 3D machinecomponents"

Florian Bartels"Steigerung der Dynamik von Laser-schneidanlagen durch Zusatzachs-systeme auf Basis hochdynamischer Strahlablenkoptiken""Increasing the dynamics of laser cutting machines by adding axes systems based on highly dynamic beam deflection optics"

3. Best scientific performance of a junior scientist

Frank Brückner"Simulationsgestützte Optimierung von mit dem Faserlaser auftragge-schweißten filigranen Interfacestruk-turen zur Verbesserung der Haftungplasmagespritzter Wärmedämm-schichten" "Simulation based optimization of fiber laser deposited filigree inter-face structures to improve the ad-hesion of plasma sprayed thermal barrier coatings"

4. Best scientific student performance

Sebastian Thieme"Flexilas – Innovative Laserstrahl-Präzisionstechnologie zum Auftrag-schweißen mit zentrischer Draht-zufuhr" "Flexilas – Innovative laser beamprecision technology for the buildupwelding with centric wire feed"

Frank Kaulfuß"Experimentelle Untersuchungen zur Abscheidung von bearbeitbarenPVD-Hartstoffschichten" "Experimental investigations to deposit PVD hard coatings that can be mechanically post processed"

Patrick Grabau"Optimierung einer Lichtbogenplas-maquelle für plasmachemische Ätzprozesse" "Optimization of an arc plasma source for plasma chemical etching processes"

5. Special award

Kerstin Zenner"Herausragende Arbeiten zur Visualisierung von wissenschaftlich-technischen Prozessen""Outstanding contributions to visu-alize scientific-technical processes"

K. Zenner receives the Special award for her out-standing contributions to the visualization of sci-entific-technical processes

F. Bartels during the bestowal ceremony of theInstitute’s award for best scientific-technical per-formances



Diploma theses

A. Bandowski(Technische Universität Dresden)

"Erarbeitung technologischer Variantenfür die Kühlschmierstoffreinigung"

"Developing technological variationsfor the cleaning of coolants and lubri-cants"

M. Busch(Technische Universität Dresden)

"Vorbehandlung und Prozessparameterzum Wachstum von leitfähigen CVD-Diamantschichten und Empfehlungeiner Markteintrittsstrategie"

"Preparation and process parametersto grow conductive CVD diamondfilms and recommendations for a mar-ket entry strategy"

F. Fräßdorf(Technische Universität Dresden)

"Fertigungsgerechte Bauteilgestaltung -Eigen- und Fremdmotorenanalyse"

"Manufacturing oriented componentdesign – Internal and external motoranalysis"

R. Freigang (Technische Universität Dresden)

"Evaluation einer Methodik zurSystemanalyse anhand einer Fallstudieam Beispiel des Laserauftrag-schweißens"

"Evaluation of a system analysismethod based on a case study on laserbuildup welding"

S. Glinka(Hochschule Bochum)

"Ermittlung von Verbesserungspoten-zialen beim Hybridschweißen von Fein-kornbaustählen durch den Einsatzeines 8 kW-Faserlasers und geeigneterOptiken"

"Improving the hybrid welding of finegrain steels by using a 8 kW fiber laserwith suitable optics"

A. Grafe(Technische Universität Dresden)

"Reproduzierbare Preformfertigung fürtextilverstärkte Kunststoffe durch Kleb-und Laserfixierung"

"Reproducible preform fabrication fortextile reinforced plastics throughadhesive and laser fixing"

J. Grübler(Hochschule Mittweida (FH))

"Untersuchungen zur optisch-spek tro -skopischen Bestimmung der Perme -abilität von Ultrabarrierematerialien"

"Optical spectroscopy investigations todetermine the permeability of ultrabarrier materials"

M. Haehnel(Technische Universität Dresden)

"Steuerung für ein konfokales laser-Scanning-Mikroskop mit einer lateralenAuflösung im Submikrometer-Bereich"

"Controller for a confocal laser micros-cope with a lateral resolution in thesub micrometer range"

S. Hampsch(Technische Universität Dresden)

"Parameteroptimierung beim Glattwal-zen zylindrischer Proben bis zu einerHärte von 55 HRC im Einstech- undDurchlaufverfahren"

"Parameter optimization for thesmooth rolling of cylindrical samplesup to a hardness of 55 HRC using theplunge cutting or pass through proces-ses"

C. Haschlar(Technische Universität Dresden)

"Qualifizierung und Entwicklung einesSystems zur automatisierten Geome-trieerfassung für das Laser-Präzisions-Auftragschweißen"

"Development and qualification ofsystem to automatically acquire thegeometry for laser precision buildupwelding processes"

H. Hillig(Hochschule für Technik und Wirt-schaft Dresden (FH))

"Herstellung von karbidhaltigen Ver-schleißschutzschichten auf Bohrkronenmittels Laser-Pulver-Auftragschweißen"

"Fabrication of carbide based wearresistant coatings on drilling crownsusing laser powder buildup welding "

H. Höfer(Technische Universität Dresden)

"Laserschweißbare Leichtbau-Bewe-gungseinheit für die Zweikopf-Laser-schneidanlagen der TruLaser Serie7000"

"Laser weldable lightweight motionunit for dual head laser cutting machi-nes of the TruLaser 7000 series"



C. Jordan(Technische Universität Dresden)

"Verfahrensoptimierung zur Herstel-lung thermisch gespritzter Hartmetall-schichten zum Einsatz unter Roll-ermüdung"

"Process optimization to fabricate ther-mal spray hard metal coatings for rol-ling fatigue reducing applications"

F. Kaulfuß(Technische Universität Dresden)

"Experimentelle Untersuchungen zurAbscheidung von bearbeitbaren PVD -Hartstoffschichten"

"Experimental investigations to depositPVD hard coatings that can be mecha-nically post processed"

C. Kowanda(Technische Universität Dresden)

"Untersuchungen zur Überführung derSchneidtechnologie von 2D-Was-serabrasivstrahlen von holzartigenWerkstoffen"

"Investigations to commercialize the2D abrasive water jet cutting technolo-gy of wood-like materials"

M. Krätzsch(Technische Universität Dresden)

"Laserinduktionsschweißen von hoch-festen Feinkornbaustählen"

"Laser induction welding of highstrength fine grain construction steels"

S. Langner(Hochschule für Technik und Wirt-schaft Dresden (FH))

"Technologieentwicklung zur Einbrin-gung nanopartikelhaltiger Suspensio-nen in den thermischen Spritzprozess"

"Technology development to introducenanoparticle containing suspensionsinto the thermal spray processes"

S. Makowksi(Technische Universität Dresden)

"Anwendungsnahe Charakterisierungvon ta-C-Schichten"

"Application relevant characterizationof ta-C coatings"

A. Naumann (Hochschule für Technik und Wirt-schaft Dresden (FH))

"Datengestützte Strategieentwicklungauf dem Gebiet der Nanotechnologie"

"Data based strategy development inthe area of nanotechnology"

M. Pfennig (Hochschule für Technik und Wirt-schaft Dresden (FH))

"Prozessentwicklung zur Reparatur von Triebwerksverdichterschaufeln ausUdimet 720"

"Process development of gear bladesmade of Udimet 720"

R. Puschmann(Technische Universität Dresden)

"Onlinemessung der Schichtdicke ther-misch gespritzer Schichten"

"Online measurements of thermalsspray coating thicknesses"

J. Richter (Hochschule für Technik und Wirt-schaft Dresden (FH))

"Untersuchungen zum Remote-Laser-strahlschneiden"

"Investigations on remoter laser beamcutting"

J. Richter (Hochschule Mittweida (FH))

"Entwickeln und Optimieren einerTechnologie zum reproduzierbarenFügen von Keramiken und Kunststof-fen mittels Laserstrahlung"

"Technological development and optimatation for the repeatable joining of ceramics and plastics bylaser beaming"

U. Richter (Technische Universität Dresden)

"Dissoziation von Stickstoff an nano-skaligen Metallpartikeln"

"Dissociation of nitrogen on nanoscalemetal particles"

T. Rönnefahrt(Hochschule für Technik und Wirt-schaft Dresden (FH))

"Konstruktive Weiterentwicklung vonStrahlteileroptiken zum Laser-Auftrag-schweißen mit Pulver und Draht"

"Continuation of the constructivedevelopment of beam splitting opticsfor laser buildup welding with powderand wire"

D. Ruhland(Hochschule Bochum)

"Ermittlung geeigneter Strahlkaustikenvon Faserlasern hoher Strahlqualitätfür das Tiefschweißen im Stahlbau"

"Determination of suitable beam cau-stics of high beam quality fiber lasersfor deep welding processes in steelconstruction"



Doctoral theses

G. Göbel(Technische Universität Dresden)

"Erweiterung der Prozessgrenzen beimLaserstrahlschweißen heißrissgefährde-ter Werkstoffe"

"Expansion of the process limits duringthe laser beam welding of hot cracksensitive materials"

G. Mäder(Technische Universität Dresden)

"Atmosphärendruck-Plasma-Beschich-tungsreaktoren"

"Atmospheric pressure plasma coatingreactors"

H. Nizard(Technische Universität Dresden)

"Untersuchung photokatalytischerBeschichtungsmaterialien. Abschei-dungsmethoden, Charakterisierung derphotokatalytischen Aktivität und Opti-mierung der Beschichtungsprozesse"

"Investigations of photo catalytic coa-ting materials. Deposition methods,characterization of the photo catalyticactivity and optimization of the deposi-tion processes"

A. Ohnesorge(Technische Universität Dresden)

"Bestimmung des Aufmischgradesbeim Laser-Pulver-Auftragschweißenmittels laserinduzierter Plasmaspektro-skopie (LIPS)"

"Determination of the mixing degreeduring the laser powder buildup wel-ding process using laser induced plas-ma spectroscopy (LIPS)"

Stipends

F.-L. TomaDocteur en Sciences pour l'IngénieurHumboldt-Stipend

J. Spatzier(Technische Universität Dresden)

"Herstellung und Charakterisierungvon karbidhaltigen Verschleißschutz-schichten mittels Laser-Pulver-Auftrag-schweißen"

"Fabrication and characterization ofcarbide based wear protective coatingsusing laser powder buildup welding"

B. Süß (Berufsakademie Sachsen, StaatlicheStudienakademie Dresden (BA))

"Prototypische Entwicklung einerkamerabasierten Prozessüberwachungfür das Laser-Pulver-Auftrags-schweißen"

"Prototype development of a camerabased process control system for laserpowder buildup welding processes"

H. Teuber(Berufsakademie Sachsen, StaatlicheStudienakademie Dresden (BA))

"Wissenschaftliche Untersuchung ver-schiedener Aspekte bei der Produktionvon 3D-Stereofilmen im Vergleich zuherkömmlicher 2D-Videotechnikanhand beispielhaft erstellter Film -szenen"

"Scientific investigations of the variousaspects of producing 3D stereo moviesin comparison to conventional 2Dvideo technologies based on fabricatedsample movie scenes"

T. Weinrich(Technische Universität Dresden)

"Entwicklung komplexer prozessnaherUrformwerkzeuge zur Untersuchungund Bewertung der Eignung derMELATO-Technologie für den Leder -faserguss"

"Scientific investigations of the variousaspects of producing 3D stereo moviesin comparison to conventional 2Dvideo technologies based on fabricatedsample movie scenes"



Participation in fairs and exhibitions

Nanotech 2008 Tokyo, Japan, February 13th - 15th, 2008

The nanotechnology competence cen-ter "Ultrathin Functional Films" and theFraunhofer IWS participated for thethird time at the world’s largest nano -technology conference. The groupexhibited at the booth of Saxony’sEconomic Development CorporationGmbH. 522 exhibitors from 23 coun-tries presented across three exhibitionhalls at the trade fair grounds "TokyoBig Sight". A new record of 49,400visitors was achieved. The competencecenter was in particular involved in thepreparation of the conference. Severalmembers actively participated withpresentations during accompanyingevents. The nano competence centerwas also represented at the AGeNTbooth, a joint exhibition of the nano -technology competence centers ofGermany.

Intec 2008 Leipzig,February 26th - 29th, 2008

The Fraunhofer IWS Dresden partici-pated at three booths during the"Intec – 11th Trade Fair for ProductionTechnology, Machine Tools and Spe-cialized Machine Building":- ALOtec Dresden GmbH and IWS

Dresden showed technologies tolaser cut and harden at the booth ofthe company Reis GmbH & Co. KGMachine Factory Obernburg.

- The initiative LiFt (Laser Integrationin Manufacturing Technology) pre-sented at the joint booth of theIndustrial and Commerce Chamberof Southwest Saxony.

- The workgroup, Adhesive Bonding,presented their portfolio at the jointbooth "Research for the Future" ofthe TU Dresden.

Lasys 2008 Stuttgart,March 4th - 6th, 2008

The new international trade show forsystem solutions in laser materials pro-cessing "Lasys 2008" was held at thenew fair grounds in Stuttgart. TheFraunhofer IWS Dresden demonstratedfor the first time the laser remote cut-ting of metallic materials. With the helpof a robot based laser system and scan-ner optics, it is possible to cut a matrixof holes (100 circles of 6.5 mm dia -meter) in less than 2 seconds out of100 μm thick stainless steel sheet metal. This corresponds to a 100 %increase in productivity if compared toconventional linear drive systems.

Hannover Industry Fair 2008April 21st - 25th, 2008

The IWS presented the latest genera-tion technologies and applications offiber lasers for laser materials process-ing using the example of laser harden-ing. The exhibition was held in Hall 5 inthe "Subcontracting" area of the sup-plying industries. A particular focus wasthe localized hardening of precisioncomponents. Larger areas can be hard-ened by using scanner optics.

The joint booth "Research for theFuture" was setup in hall 2. Here theFraunhofer IWS and the TU DresdenDepartment for Laser and SurfaceTechnology exhibited innovative solu-tions for the adhesive bonding of glassand textiles, as well as how to incorpo-rate carbon nanotubes into adhesives.

The innovation cluster "nano for pro-duction" was present at the FraunhoferSociety booth in hall 2.

Presentation of innovations in adhesive bondingtechnology at the Hannover Industry fair 2008,hall 2

The initiative LiFt was present at the Intec andexhibited at the joint booth of the IHK South-west Saxony



Laser remote cutting of thin sheet metal waspresented in a live demonstration at the Euro -blech 2008

The Free State of Saxony showed off her newdesign at the Aviation Show ILA 2008

International Aerospace ExhibitionILA 2008 Berlin,May 27th - June 1st, 2008

The IWS participated at the ILA for thethird time. The exhibition was held onthe grounds of the airport in Schoene-feld. The joint booth was organized bySaxony’s Economic Development Cor-poration with the help of the Compe-tence Center for Aerospace Technolo-gy Saxony / Thuringia e.V.

Technology developments to laserweld aircraft fuselage structures and tocharacterize mechanical, thermal andtribological properties of laser treatedaviation relevant components wereexhibited.

O&S Fair 2008 Stuttgart,June 3rd - 5th, 2008

The international trade fair for surfacecoatings O&S was also a first timeevent at the Stuttgart trade fairgrounds. This show emerged from theGalvanica fair. The Fraunhofer IWSshowed exhibits in the area of frictionreduction and photovoltaics. Due tointerest generated by the show, theinstitute received requests rangingbeyond the exhibited technologieswhich led to a lively exchange of expe-riences.

Plasma Surface Engineering PSE2008 Garmisch-Partenkirchen,September 15th - 19th, 2008

The Fraunhofer IWS participated at the11th Plasma Surface Engineering con-ference and exhibition in Garmisch-Partenkirchen. The Laser-Arc coatingtechnology and applications in thearea of wear protection were ex -hibited.

Technology Fair Euroblech 2008Hannover, October 21st - 25th, 2008

For the fourth time the IWS participat-ed in this International Technology Fairfor sheet metal processing. A jointFraunhofer booth was located in hall11. The IWS presented four topics:- laser remote cutting of thin sheet

metal and fiber laser cutting of thicksheet metal,

- laser welding of car body parts,- laser welding of lightweight metals,

for vehicle and aircraft construction- LiFt – Laser integration in manufac-

turing technology.

Fair Parts2clean 2008 Stuttgart,October 28th - 30th, 2008

The Fraunhofer alliance Cleaning Tech-nologies operated a joint booth at thisshow at which the IWS presented sys-tem technology solutions to partiallyclean components with laser beams.The special characteristics of the pre-sented solution are the integration ofthe cleaning step into the automatedmanufacturing flow, the implementa-tion of short cycle times, the cleaningof the fully mounted part prior to thesubsequent processing step and theavoidance of any solvents or othercleaning agents. This solution was

demonstrated by removing coolantand lubricant contaminations as wellas preservatives in the joints prior tolaser beam welding.

Euromold 2008 Frankfurt / M.,December 3rd - 6th, 2008

The Euromold is a trade fair for mold,die and tool makers. The FraunhoferIWS presented a 5-axes computer con-trolled milling center with an integrat-ed laser module. The module wasmounted directly in a milling spindleand presented as the main attraction.The machine can completely processparts in one setting. The processincludes the three dimensional laserbuildup welding and the mechanicalpost processing using 5-axes mill cutters.

Impressions from the first "O&S" in Stuttgart


Patents and trademarks

Patent applications 2008

[P01] T. Abendroth, H. Althues, S. Kaskel,I. Dani

"Verfahren zur Herstellung photokataly-tisch aktiver Titandioxidschichten"

Anmelde-Az.: DE 10 2008 052 098.5

[P02] F. Bartels, L. Morgenthal, T. Schwarz, T. Himmer

"Vorrichtung und Verfahren zum schnei-denden Bearbeiten von Werkstücken miteinem Laserstrahl"

Anmelde-Az.: DE 10 2008 027 524.7

[P03] H. Beese, W. Grählert, V. Hopfe

"Vorrichtung und Verfahren zur Bestim-mung der Permeationsrate mindestenseines Permeaten, durch ein eine Diffusi-onssperre bildendes Element"

Anmelde-Az.: PCT/DE2008/000904

[P04] E. Beyer, P. Pfohl

"Vorrichtung und Verfahren zur Bearbei-tung von Bauteilen"


[P05] E. Beyer, I. Jansen

"Verfahren zum stoffschlüssigen Verbin-den von Teilen mit einem Klebstoff"

Anmelde-Az.: DE 10 2008 025 891.1

[P06] E. Beyer, A. Mahrle

"Verfahren zum Schmelzschneiden vonWerkstücken mit Laserstrahlung"

Anmelde-Az.: DE 10 2008 053 397.1

[P07] B. Brenner, V. Fux, K. Merz

"Verfahren und Vorrichtung zum Herstel-len von metallischen Verbundwerkstoffenund Verbund-Halbzeugen"

Anmelde-Az.: DE 10 2008 036 435.5

[P08] S. Bretschneider, M. Melde, J. Hannweber, S. Kühn

"Laserschutzwandelelement für eineUmhausung bei Laserbearbeitungsanla-gen"

Anmelde-Az.: PCT/EP2008/006528

[P09] P. Grabau, J. Roch, V. Hopfe, I. Dani

"Verfahren und Vorrichtung zum Zündeneines Lichtbogens"

Anmelde-Az.: DE 10 2008 018 589.2

[P10] T. Himmer, F. Bartels, L. Morgenthal

"Vorrichtung und Verfahren zum Schnei-den von Werkstücken mit einem Laser-strahl"

Anmelde-Az.: DE 10 2008 025 044.9

[P11] T. Himmer, F. Bartels, T. Schwarz, L. Morgenthal

"Vorrichtung zur Bearbeitung von Werk-stücken mit einem zweidimensional aus-lenkbaren Energiestrahl"

Anmelde-Az.: DE 10 2008 032 830.8

[P12] T. Himmer, F. Bartels, L. Morgenthal,M. Lütke

"Vorrichtung und Verfahren zum Laser-strahlschneiden"


[P13] O. Jost

"Aktorelement sowie seine Verwen-dung"

Anmelde-Az.: DE 10 2008 039 757.1

[P14] S. Kaskel, C. Schrage

"Beleuchtungselement und Verfahren zuseiner Herstellung"

Anmelde-Az.: DE 10 2008 039 756.3

[P15] A. Klotzbach, L. Morgenthal, D. Pollack,F. Kretzschmar

"Verfahren zum Texturieren polymererMonofile"

Anmelde-Az.: DE 10 2008 037 317.6

[P16] A. Klotzbach, V. Fleischer, T. Schwarz,L. Morgenthal, B. Schirdewahn

"Verfahren und Vorrichtung zumSchweißen von mindestens zwei Lageneines polymeren Materials mit Laser-strahlung"

Anmelde-Az.: EP 08 017 757.9

[P17] M. Lütke, L. Morgenthal, T. Himmer, E. Beyer

"Verfahren zur trennenden Bearbeitungvon Werkstücken mit einem Laserstrahl"

Anmelde-Az.: DE 10 2008 027 130.6

[P18] M. Märcz, M. Leistner, V. Hopfe, W. Grählert, I. Dani, B. Schultrich

"Vorrichtung und Verfahren zur Herstel-lung von Kohlenstoff-Nanoröhren oderFulleren"

Anmelde-Az.: DE 10 2008 033 660.2


Patents and trademarks

[P36] G. Mäder, D. Rogler, V. Hopfe, S. Krause, R. Spitzl

"Mikrowellenplasmaquelle"

Erteilungs-Nr.: DE 10 2004 060 068

[P37] B. Schultrich, D. Schneider

"Identifikationselement"

Erteilungs-Nr.: DE 10 2006 017 155 B4

[P38] F. Sonntag

"Mikrofluidische Anordnung zur Detek-tion von in Proben enthaltenen chemi-schen, biochemischen Molekülenund/oder Partikeln"


[P39] A. Uelze, T. Himmer

"Bauteil mit miteinander verbundenenplattenförmigen Elementen sowie einVerfahren zu deren Herstellung"

Erteilungs-Nr.: DE 102 14 055 B4

Issued patents

[P28] E. Beyer, L. Morgenthal, A. Klotzbach,V. Fleischer

"Vorrichtung und Verfahren zur Bearbei-tung von Werkstücken mittels Laser-strahlung"


[P29] S. Bretschneider, M. Melde, J. Hannweber, S. Kühn

"Laserschutzwand für eine Umhausungbei Laserbearbeitungsanlagen"


[P30] I. Dani, W. Grählert, V. Hopfe, G. Mäder

"Vorrichtung und Verfahren zur opti-schen Detektion von in Abgasen chemi-scher Prozesse enthaltenen Stoffen"

Erteilungs-Nr.: EP 1 751 521 B1

[P31] T. Himmer, F. Bartels, L. Morgenthal, M. Lütke

"Vorrichtung und Verfahren zum Laser-strahlschneiden"


[P32] V. Hopfe, G. Mäder, D. Rogler, C. Schreuders

"Verfahren und Vorrichtung zurgroßflächigen Beschichtung von Sub-straten bei Atmosphärendruckbedingun-gen"

Erteilungs-Nr.: DE 102 39 875

[P33] U. Klotzbach, E. Hensel, K. Krautz, E. Beyer

"Wandelement zum Schutz vor Laser-strahlung"


[P34] U. Krzywinski, H. Rödel, I. Jansen

"Verfahren zur Strukturfixierung vontextilen Flächengebilden für Hochlei-stungs-Faserverbundbauteile und einnach diesem Verfahren hergestelltes tex-tiles Flächengebilde"

Erteilungs-Nr.: DE 10 2007 032 904

[P35] E. Lopez, I. Dani, V. Hopfe, R. Möller,M. Heintze

"Verfahren zum selektiven plasmachemi-schen Trockenätzen von auf Oberflächenvon Silicium-Wafern ausgebildetemPhosphorsilikatglas"


[P19] C.-F. Meyer

"Anordnung zur Ausbildung vonBeschichtungen auf Substraten im Vaku-um"


[P20] C.-F. Meyer

"Anode für die Bildung eines Plasmasdurch Ausbildung elektrischer Bogen-entladungen"


[P21] C.-F. Meyer

"Vorrichtung und Verfahren zur Ausbil-dung von Beschichtungen auf Substra-ten innerhalb von Vakuumkammern"


[P22] A. Meyer-Plath, M. Jäger, F. Sonntag

"Sensor für elektrophysiologische Unter-suchungen an lebenden Zellen und Ver-fahren zu seiner Herstellung"

Anmelde-Az.: DE 10 2008 056 277.7

[P23] S. Nowotny, S. Scharek

"Bearbeitungskopf mit integrierter Pul-verzuführung zum Auftragschweißenmit Laserstrahlung"

Anmelde-Az.: US 12/219,149, GB0815191.2

[P24] F. Sonntag, F. Mehringer

"Flusskanalsystem und Verfahren zumAnbinden von Analyten an Liganden"


[P25] F. Sonntag, F. Mehringer, N. Schilling,M. Jäger

"Zellkulturmesssystem und Verfahren fürvergleichende Untersuchungen an Zell-kulturen"


[P26] F.-L. Toma, L.-M. Berger, C.C. Stahr, T. Naumann, S. Langner

"Thermisch gespritzte Al2O3-Schichtenmit einem hohen Korundgehalt ohneeigenschaftsmindernde Zusätze und Ver-fahren zu ihrer Herstellung"

Anmelde-Az.: DE 10 2008 026 101.7

[P27] V. Weihnacht

"Verschleißschutzbeschichtung für aufReibung beanspruchte Oberflächen vonBauteilen sowie Verfahren zur Ausbil-dung"

Anmelde-Az.: DE 10 2008 022 039.6


Publications

rp = reviewed paper

[L01] H. Althues, S. Kaskel

"Kleine Helfer sparen intelligent Energie"

Kunststoffe 98 (2008) 9, S. 134-137

[L02] H. Althues, P. Pötschke, G.-M. Kim, S. Kaskel

"Structure and Mechanical Properties ofTransparent ZnO/PBDMA Nanocomposi-tes"

J. Nanosci. Nanotechnol. (accepted)

[L03] J. Asmussen, T.A. Grotjohn, T. Schuelke,M.F. Becker, M.K. Yaran, D.J. King, S. Wicklein, D.K. Reinhard

"Multiple Substrate Microwave Plasma-assisted Chemical Vapor DepositionSingle Crystal Diamond Synthesis"

Applied Physics Letters 93 (2008) 3, Art. 031502, S. 3

[L04] A. Ay, V.M. Swope, G.M. Swain

"The Physicochemical and Electrochemi-cal Properties of 100 and 500 nm Diameter Diamond Powders Coated withBoron-doped Nanocrystalline Diamond"

Journal of the Electrochemical Society155 (2008) 10, S. B1013-B1022

[L05] R. Banndorf, W. Diehl, U. Heckmann, H. Holescek, U. Klotzbach, S. Kondruweit-Reinema, A. Leson, M. Metzner, A. Pflug, O. Zimmer

"Thesen und Trends - Mit funktionalenOberflächen in die Zukunft"

Vakuum in Forschung und Praxis 20(2008) 4, S. 14

[L06] H. Beese, W. Grählert, R. Grübler, P. Kaspersen, A. Bohman

"Optisch-spektroskopische Bestimmungder Permeabilität von Ultrabarriere-materialien"

Fachtagung “Optische Analysenmess-technik in Industrie und Umwelt” (2008),(VDI-Berichte 2047), 2008 S. 113-120

[L07] H. Beese, S. Kaskel

"Prozessgasanalytik mittels Laserdioden-spektroskopie"

CHEManager 22 (2008) S. 17

[L08] L.-M. Berger, K. Lipp, C. Jordan, U. May,T. Naumann

"Rolling Contact Fatigue of HVOF-Spray-ed WC-Based Hardmetal Coatings "

Euro PM2008, International PowderMetallurgy Congress & Exhibition, Pro-ceedings, (2008), Mannheim, Germany,Shrewsbury, U.K.: European PowderMetallurgy Association, 1 (2008) S. 205-212, ISBN 978 1 899072 03 3

[L09] L.-M. Berger, S. Saaro, C. Jordan, T. Naumann, M. Kašparova, F. Zahálka

"HVOF-Sprayed WC-(W,Cr)2C-Ni Coatingsand Their Properties"

International Thermal Spray Conference& Exhibition (ITSC 2008), ConferenceProceedings, June 2008, Maastricht,Netherlands, Düsseldorf: DVS-VerlagGmbH, (2008) (CD-ROM),ISBN 978-3-87155-979-2, S. 229-234

[L10] L.-M. Berger, S. Saaro, T. Naumann, M. Kašparova, F. Zahálka

"Microstructure and Properties of HVOF-sprayed WC-(W,Cr)2C-Ni Coatings"

Journal of Thermal Spray Technology 17(2008) 3, S. 395-403

[L11] L.-M. Berger, S. Saaro, T. Naumann, M. Wiener, V. Weihnacht, S. Thiele, J. Suchánek

"Microstructure and Properties of HVOF-sprayed Chromium Alloyed WC-Co andWC-Ni Coatings"

Surface and Coatings Technology 202(2008) 18, S. 4417-4421

[L12] L.-M. Berger, S. Saaro, M. Woydt

"WC-(W,Cr)2C-Ni – die "unbekannte"Hartmetallschicht"

Thermal Spray Bulletin, 1 (2008) S. 39-42, ISSN 1866-6248

[L13] L.-M. Berger, C. C. Stahr

"State and Perspectives of ThermallySprayed Ceramic Coatings in the Al2O3-Cr2O3-TiO2 System"

Proceedings of the 21st InternationalConference on Surface ModificationTechnologies, September, 2007, Paris,France, Eds.: T.S. Sudarshan, M. Jeandin.(2008), Valar Docs, S. 469-478 ISBN 978-0-9817065-0-4

[L14] L.-M. Berger, C.C. Stahr, S. Saaro, S. Thiele, M. Woydt

"Dry Sliding Wear Properties of ThermalSpray Coatings in the TiO2-Cr2O3System"

Proc. Friction, Wear and Wear Protection,April, 2008, Aachen, Tagungsband

[L15] L.-M. Berger, C. C. Stahr, S. Saaro, S. Thiele, M. Woydt, N. Kelling

"High Temperature Tribology up to 7.5 m/s of Thermally Sprayed Coatingsof the TiO2-Cr2O3 System and(Ti,Mo)(C,N)-Ni(Co)"

49. Tribologie-Fachtagung, September(2008), Göttingen, Aachen: Gesellschaftfür Tribologie (GfT), (2008) Band I, S. 22/1-22/12, ISBN-10: 3-00-019670-6,ISBN-13: 978-3-00-019670-6

[L16] L.-M. Berger, F.-L. Toma, C.C. Stahr

"Thermally Sprayed Titanium Oxide Coa-tings – A Truly Multifunctional CoatingSolution"

Proc. APNFM, Januar 2008, Dresden,

[L17] E. Beyer

"High Power Laser Materials Processing- New Developments and Trends"

3rd Pacific International Conference onApplications of Lasers and Optics (PICALO) 2008, Proceedings (CD-ROM),ISBN-Nummer: 978-0-912035-89-5

[L18] E. Beyer, T. Himmer, M. Lütke, F. Bartels, A. Mahrle

"Cutting with High Brightness Lasers"

Stuttgarter Lasertage (SLT’08), Tagungs-band inkl. CD-ROM, S. 29

[L19] E. Beyer, M. Lütke, T. Himmer

"Remote-Schneiden mit brillanten Strahlquellen"

Münchener Kolloquium, Innovationenfür die Produktion,Tagungsband S. 361–370, ISBN-10: 3-8316-0844-X, ISBN-13:978-3-8316-0844-7

[L20] S. Bonß

"Laserstrahlhärten – Integration in dieFertigung ermöglicht schlanke Prozesse"

HTM Z. Werkst. Wärmebeh. Fertigung63 (2008) 3, S. 147-153

[L21] S. Bonß, J. Hannweber, U. Karsunke, M. Seifert, B. Brenner, E. Beyer

"Integrated Heat Treatment – Compari-son of Different Machine Concepts"

3rd Pacific International Conference onApplications of Lasers and Optics Peking(PICALO) 2008, VR China, Tagungs-CD

[L22] B. Brenner

"Development of New Laser WeldingTechnologies and Their Industrial Use inGermany"

Keynote presentation, AILU TechnologyWorkshop “Welding and Cutting withFibre-Delivered Laser Beams”, TWI Cam-bridge (UK), 2008, Workshop-CD

77Fraunhofer IWS Annual Report 2008

Publications

[L23] B. Brenner, S. Bonß

"Hochleistungsdiodenlaser als Werk-zeug"

7. Workshop “Industrielle Anwendungenvon Hochleistungsdiodenlasern”, IWS Dresden, 2008, Workshop-CD, ISBN 978-3-8167-7663-5

[L24] B. Brenner, D. Dittrich, J. Standfuß, B. Winderlich, J. Liebscher, J. Hackius

"Laserstrahlschweißtechnologien fürinnovative integrale Rumpfschalen zivilerGroßraumflugzeuge"

DVS-Berichte, DVS Media GmbH Düsseldorf, Band 250, S. 49-54

[L25] B. Brenner, J. Hackius, J. Standfuß, D. Dittrich, B. Winderlich, J. Liebscher

"Laser Beam Welding of Aircraft Fusela-ge Structures"

27th International Congress on Applicati-ons of Lasers and Electro Optics (ICALEO2008), Temecula (CA), Proceedings paper # 1801, S. 838-845

[L26] B. Brenner, A. Jahn, J. Standfuß

"Improved Formability and Crash Perfor-mance of Laser-Welded Structures Madeof High Strength Multiphase-Steels"

9th European Automotive Laser Applica-tion Conference (EALA 2008), Bad Nauheim, Tagungsband

[L27] B. Brenner, J. Standfuß, U. Stamm, D. Dittrich, A. Jahn, B. Winderlich

"Perspektiven für den Metallleichtbau inder Fahrzeug- und Luftfahrtindustriedurch fortgeschrittene Laserstrahl-schweißverfahren"

12. Dresdner Leichtbausymposium„Innovationsquelle Leichtbau“, Tagungsband

[L28] P. Bringmann, O. Rohr, J. Wehr, I. Jansen

"Cr+6-free Hybrid Coatings as PotentialPre-Treatment for Structural AdhesiveBonding"

Euradh 2008 / Adhesion ´08, 10th Inter-nat. Conf. Sci. & Techn. Adh. (2008)Oxford, UK, S. 105-109

[L29] F. Brückner, D. Lepski, E. Beyer

"Numerical and Experimental Investigati-on of Thermal Stresses and Distortions inthe Induction Assisted Laser Cladding"

Proceedings of the 3rd Pacific Internatio-nal Conference on Application of Lasersand Optics (PICALO 2008), Paper 206, S.88-93

[L30] F. Brückner, D. Lepski, E. Beyer

"Reduction of Thermally Induced Distortion in Laser Cladding"

Proceedings of the 2nd InternationalWorkshop on Thermal Forming and Welding Distortion, Bremen (2008)

[L31] R. Dietsch, A. König, J. Ziemer

"Multischicht-Röntgenoptiken: Präzisionim Nanometerbereich"

Fokus Technologie: Chancen erkennen -Leistungen entwickeln (2008) S. 349-364, Hrg.: H.-J. Bullinger,ISBN 978-3-446-41739-9

[L32] D. Dittrich, E. Beyer, B. Brenner, J. Standfuß, B. Winderlich, J. Hackius

"Progress in Laser Beam Welding ofAircraft Fuselage Panels / Skin-Skin-Connections"

27th International Congress on Applica-tions of Lasers and Electro Optics (ICALEO 2008), Temecula (CA), USA,Proceedings paper # 1804, S. 863-871

[L33] D. Dittrich, B. Brenner, B. Winderlich, G. Kirchhoff, J. Hackius

"New Weld Seam Design for AdvancedJoining Techniques to Improve Safetyand to Reduce Structural Weight"

Aircraft Structural Design Conference,Liverpool (UK) (2008) Proceedings

[L34] J. Drechsel, S. Weinhold, J. Bachale, R. Ebert, H. Exner, S. Bonß, C. Zellbeck

"Initiative LiFt - Lasertechnologie-integration in die Fertigungstechnik"

Laser Magazin 6 (2008) S. 40-41

[L35] J. Dubský, P. Chráska, B. Kolman, C. C. Stahr, L.-M. Berger

"Formation of Corundum Phase in Plas-ma Sprayed Alumina Coatings"

Proceedings edited by Materials Austra-lia, Thermal Processing and SurfaceEngineering: Key Activities in the GlobalKnowledge Economy, The 16th Interna-tional Federation for Heat Treatmentand Surface Engineering (IFHTSE) Con-gress, Brisbane, Australien 2007, S. 62. ISBN 978 1 876855 31 2

[L36] J. Dubský, P. Chráska, B. Kolman, C. C. Stahr, L.-M. Berger

"Formation of Corundum Phase in Plas-ma Sprayed Alumina"

Journal "Materials Technology: Advan-ced Performance Materials", ManeyPublishing, London, UK

[L37] S. Eckert, S. Nowotny, A. Mehlhorn, A. Klöden, D. Kochan

"Laserauftragsschweißen im Werkzeug-bau"

Der Stahlformenbauer 25 (2008) 5, S. 96-104

[L38] H.-J. Fecht, A. Leson, B. Michel, M. Werner

"Advanced Adhesives Based on CarbonNanotube Technology"

mst-news No. 3/08, Juni 2008, S. 28-29

[L39] V. Fux, K. Merz, B. Brenner

"Laser-Walzplattieren erzeugt attraktiveWerkstoffpaarungen"

Maschinenmarkt (2009) 5, S. 42-45

[L40] P. Gawlitza, S. Braun, G. Dietrich, M. Menzel, S. Schädlich, A. Leson

"Ion Beam Sputtering of Multilayer X-Ray Optics"

Annual meeting of Spie Optics & Photo-nics, San Diego, USA, (2008), procee-dings of SPIE 7077-2

[L41] L. Girdauskaite, S. Krzywinski, H. Rödel,R. Böhme, I. Jansen

"Complex Shaped Dry Textile Preformsfor High Quality Composites"

2nd Aachen-Dresden International Textile Conference, (2008) Dresden

[L42] L. Girdauskaite, S. Krzywinski, H. Rödel,R. Böhme, I. Jansen

"Possibilities for the Production of Com-plex Shaped Dry Textile Performs forHigh Quality Composites"

8th AUTEC conference, (2008) Biella, Italien, Vorträge mit Proceedings

[L43] G. Göbel

"Erweiterung der Prozessgrenzen beimLaserstrahlschweißen heißrissgefähr -deter Werkstoffe"

Stuttgart, Fraunhofer IRB Verlag, 2008,Zugl.: Dresden, TU, Diss., 2007, ISBN 3-8167-7671-X ISBN 978-3-8167-7671-0

[L44] G. Göbel, J. Standfuß, B. Brenner

"Engspaltschweißen mit hohem Aspekt-verhältnis"

Laser und Produktion, Spezial: Faserla-ser, Sonderheft 2008, S. 20-22


[L45] W. Grählert

"Laserdiodenspektroskopie: ein selekti-ves hoch empfindliches Werkzeug zurSpurengasanalytik"

Ingenieurnachrichten 5 (2008) S. 6

[L46] W. Grimm, V. Weihnacht

"Super Hard Carbon Coatings Depositedby Pulsed DC-Arc-Process"

11th International Conference on PlasmaSurface Engineering (PSE 2008)Garmisch-Partenkirchen, TagungsbandPSE 2008, S. 94

[L47] U. Heckmann, R. Bandorf, W. Diehl, H. Holeczek, U. Klotzbach, S. Kondruweit-Reinema, A. Leson, M. Metzner, A. Pflug, O. Zimmer

"Produktionstechnik für funktionaleOberflächen: Perspektiven, Forschungs-und Handlungsbedarf"

wt Werkstattstechnik online 98 (2008)6, S. 481-485

[L48] P. Herwig

"Materialbearbeitung hoch reflektiverWerkstoffe"

Laser-Magazin (2008) 5, S. 9-11

[L49] S. Houdková, F. Zahálka, M. Kašparová,L.-M. Berger

"Tribological Behaviour of ThermallySprayed Coatings at Elevated Tempera-tures"

International Thermal Spray Conference& Exhibition (ITSC 2008), ConferenceProceedings, Düsseldorf: DVS-VerlagGmbH, (2008), CD, S. 1497-1502,ISBN 978-3-87155-979-2

[L50] D. Hrunski, A. Gordijn, U. Stickelmann,T. Kilper, W. Appenzeller, W. Grählert,H. Beese

"Analysis and Minimization of PlasmaProcess Instabilities During Thin SiliconFilms Deposition"

Photovoltaics International, 4 (2008)

[L51] A. Jahn, M. Krätzsch, B. Brenner

"Laserstrahlschweißen hochfester Fein-kornbaustähle mit werkstoffangepassterTemperaturführung"

DVS-Bericht, DVS Media GmbH Düsseldorf, Band 250, S. 215-220

[L52] A. Jahn, M. Krätzsch, B. Brenner

"Induction Assisted Laser Beam Weldingof HSLA Steel Sheets"

International Scientific Colloquium“Modelling for Electromagnetic Proces-sing”, (2008), Proceedings S. 195-200

[L53] I. Jansen, J.-S. Pap, R. Rechner

"8. Kolloquium Gemeinsame Forschungin der Klebtechnik"

8. Kolloquium Gemeinsame Forschungin der Klebtechnik, (2008), Frankfurt,Vorträge mit Proceedings, S. 38-41

[L54] I. Jansen, P. Pötschke, F. Wehnert

"Integration of Carbon Nanotubes intoAdhesives"

Euradh 2008 / Adhesion ´08, 10th Inter-nat. Conf. Sci. & Techn. Adh. 2008,Oxford, UK, S. 355-359

[L55] I. Jansen, R. Rechner

"Einsatz des Diodenlasers zur Kanten-leimung"

7. Workshop "Industrielle Anwendungvon Hochleistungsdiodenlasern" (2008)IWS Dresden, Vorträge mit Proceedings

[L56] rp I. Jansen, D. Schneider, R. Haßler

"Laser-Acoustic, Thermal and Mechani-cal Methods for Investigations of BondLines"

International Journal of Adhesion &Adhesives 29 (2009) S. 210–216

[L57] J. Kaspar, J. Bretschneider, S. Bonß, B. Winderlich, B. Brenner

"Laser Nitriding: A Promising Way toImprove the Cavitation Erosion Resistance of Components Made of Titanium Alloys"

Symp. On Friction, Wear and Wear Pro-tection, Aachen, (2008), (im Druck)

[L58] D. King, M. K. Yaran, T. Schuelke, T.A. Grotjohn, D. K. Reinhard, J. Asmussen

"Scaling the Microwave Plasma-AssistedChemical Vapor Diamond DepositionProcess to 150-200 mm Substrates"

International Conference on New Dia-mond and Nano Carbons (NDNC 2007)Proceedings : Amsterdam : Elsevier,2008, S. 520-524 (Diamond and relatedmaterials 17. 2008, Nr. 4-5)

[L59] U. Klotzbach

"Schnelligkeit und Präzision"

Mikroproduktion (2008) 2, S. 26-29

[L60] U. Klotzbach, M. Panzner, G. Wiedemann

"Potential and Limitations of Laser Tech-nology in Restoration of Metallic Objectsof Art and Cultural Heritage"

Materials and corrosion 59 (2008) 3, S. 220-227

[L61] S. Kühn

"Neue aktive Laserschutzwand für Laserhöchster Brillianz"

Laser-Magazin (2008) 2, S. 28-29

[L62] S. Kühn

"Aktiver Laserschutz mit Heißleiter"

Photonik No. 4 (2008), S. 13

[L63] S. Kühn, J. Hannweber, B. Brenner, E. Beyer

"A Novel Active Laser Safety Shield"

27th International Congress on Applica-tions of Lasers and Electro Optics (ICALEO 2008), Proceedings paper #208, S. 113-116

[L64] D. Lepski, F. Brückner

"Laser Cladding"

Chapter 8 of the book by J.M. Dowden(Ed.) „The Theory of Laser Materials Pro-cessing“, Canopus Publishing Limited,Bristol, (im Druck)

[L65] A. Leson

"Neue-Nano-Ideen für die Industrie"

Konstruktion, 3 (2008) IW12

[L66] A. Leson

"Nanotechnologie - Von der Vision zurWirklichkeit"

Forschung / Karriere / Kompetenz Nano-technologie aktuell, IWV, 1 (2008) S. 50-53

[L67] A. Leson

"Zukunftsthema Nanotechnologie"

Ingenieure in Sachsen 01 (2008) S. 10-11

[L68] D. Linaschke, M. Leistner, G. Mäder, W. Grählert, I. Dani, S. Kaskel

"In-line Plasma-chemical Etching ofCrystalline Silicon Solar Wafers atAtmospheric Pressure"

Eingereicht in IEEE

Publications

79

[L77] A. Mahrle, F. Bartels, E. Beyer

"Theoretical Aspects of the Process Efficiency in Laser Beam Cutting withFibre Lasers"

Proceedings of the 27th InternationalCongress on Applications of Lasers &Electro-Optics (ICALEO), 2008, Paper2006

[L78] A. Mahrle, E. Beyer

"Derivation of Optimal Processing Para-meters for Conduction Mode LaserBeam Welds by Simulation"

Proceedings of the 3rd Pacific Internatio-nal Conference on Applications ofLasers and Optics, Paper P223, S. 936-941

[L79] P. Marsik, P. Verdonck, D. Schneider, D. de Roest, S. Kaneko, M. R. Baklanov

"Spectroscopic Ellipsometry and Ellipso-metric Porosimetry Studies of CVD Low-k Dielectric Films"

In: Arwin, H.: Papers presented at the4th International Conference on Spec-troscopic Ellipsometry, (ICSE4), Stock-holm, Sweden, 2007, Weinheim: Wiley-VCH, 2008, S.1253-1256, (Physica sta-tus solidi. (c), Current topics in solid sta-te physics, (2008), Nr.5)

[L80] J.J. Narendra, T.A. Grotjohn,J. Asmussen

"Microstripline Applicators for CreatingMicroplasma Discharges with Micro-wave Energy"

Plasma sources science & technology 17(2008) 3, Art. 035027, S. 11

[L81] S. Nowotny, S. Scharek, S. Thieme, R.A. Gnann

"FLEXILAS – Laser-Präzisionstechnologiezum Auftragschweißen mit zentrischerWerkstoffzufuhr"

DVS-Berichte Band 250, S. 318-322,DVS Media GmbH, Düsseldorf, 2008

[L82] B. van Pham, H.-A. Bahr, U. Bahr, H. Balke, H.-J. Weiß

"Global Bifurcation Criterion for Oscillatory Crack Path Instability"

Physical Review. E 77 (2008) 6, Art.066114, S. 10

[L83] B. Pollakowski, B. Beckhoff, B. F. Reinhardt, S. Braun, P. Gawlitza

"Speciation of Deeply Buried TiOx Nano-layers with Grazing-Incidence X-Ray Flu-orescence Combined With a Near-EdgeX-Ray Absorption Fine-Structure Investi-gation"

Physical Review B 77 (2008) 23, Art.235408, S. 11

[L69] D. Linaschke, M. Leistner, G. Mäder, W. Grählert, I. Dani, S. Kaskel

"In-line Plasma-chemical Etching ofCrystalline Silicon Solar Wafers at Atmos-pheric Pressure and FT-IR SpectroscopicProcess Control"

Photovoltaics International, 4 (2008) S. 47 - 53

[L70] S. Lipfert, S. Braun, P. Gawlitza, J. Schmidt, A. Leson

"Inner Coating of EUV Collector Shells"

11th International Conference on PlasmaSurface Engineering (PSE20008)Tagungsband PSE 2008, S. 332

[L71] S. Lipfert, P. Gawlitza, S. Braun, A. Leson

"Application of Large Ion Beam Techno-logy for Optical Coatings"

11th International Conference on PlasmaSurface Engineering (PSE2008)Tagungsband PSE 2008, S. 157

[L72] M. Lütke

"Aus der Faser in die Ferne: Laser-Remote-Schneiden mit dem Faserlaser"

Photonik 40 (2008) 1, S. 12

[L73] M. Lütke, T. Himmer

"Fein- und Dickbleche Schneiden mitdem Faserlaser"

Laser und Produktion, Spezial: Faserlaser, Sonderheft 2008, S. 18-19

[L74] M. Lütke, T. Himmer

"Remote-Schneiden mit dem Faserlaserermöglicht hohe Konturgeschwindigkei-ten"

Maschinenmarkt, Ausgabe 41 (2008), S. 100-102

[L75] M. Lütke, A. Mahrle, T. Himmer, L. Morgenthal, E. Beyer

"Remote-Cutting – A Smart SolutionUsing the Advantages of High Brightness Lasers"

27th ICALEO 2008, Tagungsband, Paper2005

[L76] G. Mäder

"Atmosphärendruck-Plasma-Beschich-tungsreaktoren"

Stuttgart : Fraunhofer IRB Verlag, 2008Zugl.: Dresden, Univ., Diss., 2008ISBN 3-8167-7656-6 ISBN 978-3-8167-7656-7

[L84] L. Prager, P. Marsik, L. Wennrich, M. R. Baklanov, S. Naumov, L. Pistol, D. Schneider, J. W. Gerlach, P. Verdonck, M. R. Buchmeiser

"Effect of Pressure on Efficiency of UVCuring of CVD-Derived Low-K Materialat Different Wavelengths"

European Workshop on Materials forAdvanced Metallization (MAM 2008), In: Schulz, S.E.: Proceedings of theWorkshop: A single-session workshopdevoted to materials research, materialsproperties and interactions, 2008, Dres-den Amsterdam : Elsevier, 2008, S. 2094-2097, (Microelectronic engineering85.2008, Nr.10)

[L85] M. Raaif, F.M. El-Hossary, N.Z. Negm, S. M. Khalil, A. Kolitsch, D. Höche, J. Kaspar, S. Mändl, P. Schaaf

"CO2 Laser Nitriding of Titanium"

Journal of Physics. D. Applied Physics 41 (2008) 8, S. 8

[L86] R. Rechner, I. Jansen

"Laservorbehandlung von Leichtmetallenvor dem Kleben"

6. Praxisseminar Kleben, (2008) Jena,Vorträge mit Proceedings

[L87] M. Reichmann, O. Throl, J. Rank, V. Uhlig, E. Beyer, G. Walter

"Kontrolliertes Entbindern in mikrowel-len-unterstützten Thermoprozess-anlagen"

Elektrowärme International 3 (2008), S. 203-209

[L88] R. Schedewy, E. Beyer, B. Brenner, A. Grimm, D. Dittrich, J. Standfuß

"Laser Beam Welding of High StiffnessLight Weight Structures Generated byScanned Fiber Laser"

27th International Congress on Applica-tions of Lasers and Electro Optics, (ICALEO) Temecula (CA), USA, 2008,Proceedings paper # 609, S. 332-339

[L89] H.-J. Scheibe, M. Leonhard, A. Leson,C.-F. Meyer, T. Stucky, V. Weihnacht

"Abscheidung superharter Kohlenstoff-schichten mittels Laser-Arco® auf demWeg vom Labor in die industrielle Serienfertigung"

Vakuum in Forschung und Praxis 20(2008) 6, S. 26-31

Publications



Publications

[L90] H.-J. Scheibe, V. Weihnacht, T. Stucky

"Verschleissschutz - Extrem harte Koh-lenstoffschichten unter Fertigungsbedin-gungen abscheidbar"

Maschinenmarkt. MM, das Industriema-gazin (2008) 25, S. 22-24

[L91] D. Schneider, E. Hensel, A. Leson

"Testing Thin Films and Surfaces"

NanoS Guide 2008, Wiley-VCH Verlag,S. 20-26

[L92] D. Schneider, A. Leson

"Evaluating Thin Films and Material Sur-faces by the Surface Acoustic WaveTechnique LAwave"

MicroCar 2008, Micromaterials andNanomaterials, 8 (2008)

[L93] B. Schultrich, V. Weihnacht

"Tribologisches Verhalten von hartenund superharten Kohlenstoffschichten"


[L94] C. C. Stahr, L.-M. Berger, M. Herrmann,D. Deska

"Corrosion of Alumina-Based Coatings"

International Thermal Spray Conference& Exhibition (ITSC 2008), ConferenceProceedings, Düsseldorf: DVS-VerlagGmbH, (2008), CD, S. 374-377, ISBN 978-3-87155-979-2

[L95] C. C. Stahr, L.-M. Berger, M. Herrmann,D. Deska

"Korrosion thermisch gespritzter Schich-ten auf der Basis von Aluminiumoxid"

Tagungsband zum 11. Werkstofftechni-schen Kolloquium in Chemnitz, (2008)Schriftenreihe "Werkstoffe und werk-stofftechnische Anwendungen", Band31, Herausgeber: B. Wielage, Chemnitz:TU Chemnitz, (2008) S. 115-122,ISBN: 978-3-00-025648-6, ISSN: 1439-

1597

[L96] C. C. Stahr, L.-M. Berger, S. Thiele

"Mikrostruktur und EigenschaftenHVOF-gespritzter Schichten im SystemTiO2 - Cr2O3"

Materialwissenschaft und Werkstoff-technik 39 (2008) 1, S. 24-28

[L97] C. C. Stahr, L.-M. Berger, S. Thiele, S. Saaro

"Thermally Sprayed TiO2-Cr2O3 Coatingswith Multifunctional Properties"

International Thermal Spray Conference& Exhibition ITSC 2008, Conference Proceedings, Düsseldorf: DVS-VerlagGmbH, (2008), CD, S. 1114-1119,ISBN 978-3-87155-979-2

[L98] C. C. Stahr, L.-M. Berger, F.-L. Toma

"Keramische Schichten im SystemAl2O3-Cr2O3-TiO2 – ausgewählte Entwicklungstendenzen"

Tagungsband zum 4. GTV KolloquiumThermisches Spritzen (2008), Lucken-bach, Hrg.: A. Schwenk, Luckenbach:GTV-Verschleiss-Schutz GmbH, (2008) S.56-63, ISSN 1610-0530

[L99] C. C. Stahr, L.-M. Berger, F.-L. Toma, M. Herrmann, D. Deska, G. Michael


Materialwissenschaft und Werkstoff-technik, 39 (2008) 12, S. 892-896

[L100] J. Standfuß, U. Stamm, G. Göbel, S. Schrauber, B. Brenner

"Future Powertrain Welding ApplicationsDriven by Fiber Lasers"

ALAW 2008, Automotive Laser Applica-tion Workshop 2008, Plymouth (MI),USA, Tagungsband

[L101] O. Stelling, N. Ellendt, V. Uhlenwinkel,P. Krug, O. Keßler, H.-W. Zoch, B. Commandeur

"Einfluss des primär ausgeschiedenenMg2Si-Anteils sowie dessen Verteilungauf die Eigenschaften von sprühkom-paktierten AlMgSiCu-Legierungen"

Härterei-Technische Mitteilungen: HTM63 (2008) 5, S. 276-283

[L102] T. Stucky, V. Weihnacht, S. Bräunling

"Potenzial von ta-C-Schichten für dieTrockenumformung"

Europäische ForschungsgesellschaftDünne Schichten e.V. -EFDS- ; Fraunho-fer-Institut für Schicht- und Ober-flächentechnik -IST-, Braunschweig ;Fraunhofer-Institut für Werkstoff- undStrahltechnik -IWS-, Dresden:Kohlenstoffschichten- TribologischeEigenschaften und Verfahren zu ihrerHerstellung. 3. EFDS Workshop 2008,Dortmund, S. 10

[L103] A. Techel

"Mit dem Laser Energie sparen"

Laser + Produktion 2008, S. 12-14

[L104] A. Techel, L.-M. Berger, V. Weihnacht

"Hart im Nehmen"

Metalloberfläche (mo), 62 (2008) 9, S. 30-32, ISSN 0026-0797

[L105] A. Techel, C. Zellbeck

"Im Blickpunkt – Deutschlands Elite-Institute – Fraunhofer-Institut für Werk-stoff- und Strahltechnik IWS Dresden"

ISSN 1614-8185

[L106] F.-L. Toma, L.-M. Berger, D. Jacquet, D. Wicky , I. Villaluenga, Y. R. de Miguel, J. S. Lindeløv

"Vergleichende Untersuchungen zu denphotokatalytischen Eigenschaften vonthermisch gespritzten Titanoxidschichtenaus Pulvern und Suspensionen"

Tagungsband zum 11. Werkstofftechni-schen Kolloquium in Chemnitz, Schrif-tenreihe "Werkstoffe und werkstoff-technische Anwendungen", Band 31,Hrg.: B. Wielage, Chemnitz: TU Chem-nitz (2008) S. 107-114, ISBN: 978-3-00-025648-6, ISSN: 1439-1597

[L107] F.-L. Toma, L.-M. Berger, T. Naumann,S. Langner

"Microstructures of NanostructuredCeramic Coatings Obtained by Suspension Thermal Spraying"

Surface and Coatings Technology 202(2008) 18, S. 4343-4348

[L108] F.-L. Toma, L.-M. Berger, T. Naumann,S. Langner

"Characterisation of Ceramic Nanostruc-tured Coatings Prepared by ThermalSpraying of Suspensions"

International Thermal Spray Conference& Exhibition (ITSC 2008), ConferenceProceedings, Düsseldorf: DVS-VerlagGmbH, (2008), CD, S. 429-434, ISBN 978-3-87155-979-2

[L109] F.-L. Toma, G. Bertrand, D. Klein, C. Meunier, S. Begin

"Development of Photocatalytic ActiveTiO2 Surfaces by Thermal Spraying ofNanopowders"

Journal of Nanomaterials. Online unterhttp://www.hindawi.com/journals/jnm/index.html 2008 (2008), Art. 384171, S. 8


Publications

[L110] A.M. Urbanowicz, B. Meshman, D. Schneider, M. R. Baklanov

"Stiffening and Hydrophilisation of SOGLow-K Material Studied by EllipsometricPorosimetry, UV Ellipsometry and Laser-Induced Surface Acoustic Waves"

Physica status solidi. A, 205 (2008) 4, S. 829-832

[L111] V. Weihnacht

"Mechanisch-tribologisch angepasste ta-C-basierte-Schichtsysteme"

In: Europäische ForschungsgesellschaftDünne Schichten e.V. -EFDS- ; Fraunho-fer-Institut für Schicht- und Ober-flächentechnik -IST-, Braunschweig ;Fraunhofer-Institut für Werkstoff- undStrahltechnik -IWS-, Dresden:Kohlenstoffschichten- TribologischeEigenschaften und Verfahren zu ihrerHerstellung. 3. EFDS Workshop 2008,Dortmund, S. 9

[L112] V. Weihnacht, A. Brückner

"Optimized ta-C-Based Coating Systemsfor Lubricated Conditions"

Seminar HANSER-Verlag "FunktionaleSchichten", Fellbach, März, 2008,Tagungsband

[L113] V. Weihnacht, A. Brückner


Workshop "Friction, Wear and Wearprotection", Aachen, 2008, Tagungs-band

[L114] V. Weihnacht, A. Brückner, S. Bräunling

"ta-C beschichtete Werkzeuge für dieTrockenumformung von Aluminium-blechen"


[L115] V. Weihnacht, A. Brückner, S. Bräunling

"Diamantartige Kohlenstoffschichten mitPotenzial zur Trockenumformung"

Europäische Forschungsgesellschaft fürBlechverarbeitung (Kolloquium) In: Europäische Forschungsgesellschaftfür Blechverarbeitung e.V., EFB:Intermezzo der Werkstoffe. Die Chanceder Wahl für Konstrukteure und Planer,EFB, 2008, S. 47-52

[L116] V. Weihnacht, H.-J. Scheibe

"Friction and Wear Behaviour of Modi-fied Diamondlike Carbon Films"

16th International Colloquium TribologyStuttgart, Januar, 2008, Tagungsband

[L117] V. Weihnacht, H.-J. Scheibe, A. Leson

"ta-C and Modified ta-C:X Films forDemanding Tribological Applications"

11th International Conference on PlasmaSurface Engineering (PSE2008)Garmisch-Partenkirchen, September2008, Tagungsband PSE 2008, S. 90

[L118] B. Weller, I. Jansen, S. Tasche

"Adhesive Joints with Acrylates in GlassStructures"

Euradh 2008 / Adhesion ´08, 10th Inter-nat. Conf. Sci. & Techn. Adh., Septem-ber 2008, Oxford, UK, S. 309-312

[L119] S. Winkler, S. Braun, P. Gawlitza, D. C. Meyerl

"Fabrication and Characterization ofMultilayered Thermal Barrier Coatings"

11th International Conference on PlasmaSurface Engineering (PSE2008)Garmisch-Partenkirchen,Tagungsband PSE 2008, S. 310

[L120] W. L. Xu, J.-S. Pap, J. Bronlund

"Design of a Biologically Inspired ParallelRobot for Foods Chewing"

IEEE transactions on industrial electro-nics 55 (2008) 2, S. 832-841

[L121] W.L. Xu, D.J. Torrance, B.Q. Chen, J. Potgieter, J.E. Bronlund, J.-S. Pap

"Kinematics and Experiments of a Life-Sized Masticatory Robot for Characteri-zing Food Texture"

IEEE transactions on industrial electro-nics 55 (2008) 5, S. 2121-2132

[L122] O. Zimmer, F. Kaulfuß

"Hard Coatings with Elevated FilmThickness Prepared by PVD"

11th International Conference on PlasmaSurface Engineering (PSE2008),Tagungsband PSE 2008, S. 537

[L123] Fraunhofer-Institut für Werkstoff- undStrahltechnik IWS, Dresden

"4. Internationaler Workshop "Faserla-ser" 2008, CD-ROM, 5.-6. November2008, Fraunhofer IWS Dresden"

Stuttgart: Fraunhofer IRB Verlag, 2008ISBN 978-3-8167-7853-0

[L125] Fraunhofer-Institut für Werkstoff- undStrahltechnik -IWS-, Dresden

"7. Workshop "Industrielle Anwendun-gen von Hochleistungs-Diodenlasern"2008, CD-ROM, 24. bis 25. Juni 2008 inDresden"

Stuttgart : Fraunhofer IRB Verlag, 2008ISBN 978-3-8167-7663-5


is = invited speakers

[T01] T. Abendroth, H. Althues, S. Kaskel

"Abscheidung von photokatalytisch aktiven Titandioxidschichten bei niedrigen Temperaturen mittels Atmosphärendruck CVD"

4. Thüringer Grenz- und Oberflächen-tage, Jena, September 2008

[T02] T. Abendroth, H. Althues, S. Kaskel

"Chemische Dampfphasenabscheidung(CVD) von funktionellen Oxidschichtenauf Polymeroberflächen bei Atmosphärendruck"

16. Neues Dresdner VakuumtechnischesKolloquium, Dresden, Oktober 2008

[T03] H. Althues, T. Abendroth, I. Dani, S. Kaskel

"Atmospheric Pressure PECVD for Cost-Saving, Continuous Deposition of ThinFilms"

7th International Conference on Coatings on Glass & Plastics, Eindho-ven/Veldhoven, Niederlande, Juni 2008

[T04] H. Beese, W. Grählert, J. Grübler, P. Kaspersen, A. Bohman

"Optisch-spektroskopische Bestimmungder Permeabilität von Ultrabarriere-materialien"

6th Conference on Optical AnalysisTechnology (OPTAM), Leverkusen, September 2008

[T05] H. Beese, E. Lopez, W. Grählert, I. Dani,V. Hopfe

"Characterisation of Photovoltaic Pro-duction Processes by Infrared Spectro -scopy"

1st European Conference on ProcessAnalytics and Control Technology(EUROPACT), Frankfurt/M., 22.–25. April2008

[T06] is L.-M. Berger

"Thermisch gespritzte Beschichtungslö-sungen für die Antriebstechnik"

Forschungsvereinigung Antriebstechnikdes VDMA, Frankfurt/M. 17. Januar 2008

[T07] is L.-M. Berger

"Neue Möglichkeiten für thermischgespritzte Hartmetallschichten"

Thermisches Spritzen 3-Ländereck desSchweizer Verbandes für Schweisstech-nik, Basel, 28. Oktober 2008

[T08] L.-M. Berger, K. Lipp, C. Jordan, U. May, T. Naumann

"Rolling Contact Fatigue of HVOF-Spray-ed WC-based Hardmetal Coatings"

International Powder Metallurgy Con-gress & Exhibition, Mannheim, 29. Sep-tember - 1. Oktober 2008,

[T09] L.-M. Berger, S. Saaro

"Oxidation of (Ti,Mo)(C,N)-Based HVOF-Sprayed Hardmetal Coatings"

International Conference on the Scienceof Hard Materials, Montego Bay, Jamai-ca, 10.-14. März 2008,

[T10] L.-M. Berger, S. Saaro, C. Jordan, T. Naumann, M. Kašparova, F. Zahálka

"HVOF-Sprayed WC-(W,Cr)2C-Ni Coatings and Their Properties"

International Thermal Spray Conference& Exhibition, Maastricht, Niederlande 2.-4. Juni 2008

[T11] L.-M. Berger, C.C. Stahr, S. Saaro, S. Thiele, M. Woydt

"Dry Sliding Wear Properties of ThermalSpray Coatings in the TiO2-Cr2O3System"

Friction, Wear and Wear Protection,Aachen, 9.-11. April, 2008

[T12] L.-M. Berger, C.C. Stahr, S. Saaro, S. Thiele, M. Woydt, N. Kelling

"High Temperature Tribology up to 7.5 m/s of Thermally Sprayed Coatingsof the TiO2-Cr2O3 System and(Ti,Mo)(C,N)-Ni(Co)"

49. Tribologie-Fachtagung, Göttingen,22.-24. September 2008

[T13] L.-M. Berger, V. Weihnacht, S. Saaro, R. Schwetzke

"Microstructure and Dry Sliding WearProperties of HVOF-Sprayed HardmetalCoatings with Thin Film Topcoats"

Nordtrib 2008, 13th Nordic Symposiumon Tribology, Tampere, 10.-13. Juni 2008

[T14] E. Beyer

"High Power Laser Materials Processing- New Developments and Trends"

3rd Pacific International Conference onApplications of Lasers and Optics (PICALO 2008), Peking, China, 16.–18.April 2008

[T15] E. Beyer, T. Himmer, M. Lütke, F. Bartels, A. Mahrle

"Cutting with High Brightness Lasers"

Stuttgarter Lasertage (SLT’08), Stuttgart,4.-6. März 2008

[T16] E. Beyer, M. Lütke, T. Himmer

"Remote-Schneiden mit brillantenStrahlquellen"

Münchener Kolloquium, Innovationenfür die Produktion, München, 9. Oktober 2008

[T17] S. Bonß

"LiFt - Laserintegration in die Fertigungstechnik"

SIT – Ingenieurtag, Chemnitz, 27. Juni2008

[T18] S. Bonß

"LiFt - Prozesseffizienz durch Laser -integration"

Innovationabend der Firma euro-engineering, Chemnitz, 25. September2008

[T19] S. Bonß, J. Hannweber, U. Karsunke, S. Kühn, M. Seifert, E. Beyer, G. Drollinger

"Prozesskettenverkürzung durch inte-griertes Laserstrahlhärten in Drehma-schinen"

Härterei-Kolloquium 2008, Wiesbaden,8.-10. Oktober 2008

[T20] S. Bonß, J. Hannweber, U. Karsunke, S. Kühn, M. Seifert, E. Beyer, G. Drollinger

"Integrated Laser Beam Hardening inTurning Machines for Process ChainReduction"

27th International Congress on Applica-tions of Lasers & Electro-Optics (ICALEO2008), Temecula (CA), USA, 20.-23.Oktober 2008

[T21] S. Bonß, J. Hannweber, U. Karsunke, M. Seifert, B. Brenner, E. Beyer

"Integrated Heat Treatment - Compari-son of Different Machine Concepts"

3rd Pacific International Conference onApplications of Lasers and Optics (PICALO 2008), Peking, China, 16.-18. April 2008

[T22] S. Braun

"Application of Nanometer PrecisionCoatings for EUV Lithography and X-RayAnalytics"

NanoTech 2008, Tokyo, Japan, 13.-15. Februar 2008

Conference presentations



[T23] S. Braun

"High Precision Nanoscaled Coatings forOptics"

Seminars and Lab tours “Nanotechnolo-gies for Energy and Energy Efficiency”Dresden, 13. März 2008

[T24] S. Braun, P. Gawlitza, M. Menzel, S. Schädlich, A. Leson

"Figuring of Superpolished Substrates byHigh-Precision Coatings"

9th International Conference on the Physics of X-ray Multilayer Structures(PXRMS), Montana, USA, 3.-7. Februar 2008

[T25] S. Braun, S. Schädlich, A. Leson

"Multilayer Laue Lenses: A NewApproach for Nanometer Focusing andX-Ray Microscopy"

4th Workshop on “Advanced Nanoma-terials”, Wroclaw, Polen, 27.-28. Okto-ber 2008

[T26] S. Braun, E. Zschech, W. Yun

"Nano-Röntgentomographie für Prozesskontrolle und Fehleranalyse inder Halbleiterindustrie"

Industrielle ComputertomographieTagung, Wels, Österreich, 27.-28. Februar 2008

[T27] B. Brenner

"Neue Laserstrahlschweißverfahren inForschung und Industrie"

BIC-Fachforum „Trends und Entwicklun-gen in der Laserbearbeitung – NeueMöglichkeiten für Unternehmen derRegion“, Zwickau,19. Januar 2008

[T28] B. Brenner

"Development of New Laser WeldingTechnologies and Their Industrial Use inGermany"

Keynote presentation, AILU TechnologyWorkshop “Welding and Cutting withFibre-Delivered Laser Beams”, TWI Cam-bridge, UK, 20. Februar 2008

[T29] B. Brenner

"Neueste laserbasierte Fügeverfahren inForschung und Industrie"

Materialforschungstag des Materialfor-schungsverbundes Dresden, „EffizienterLeichtbau durch einsatzgerechte Werk-stoffauswahl“(Intec 2008), Leipzig, 29. Februar 2008

[T30] B. Brenner

"Aktuelle Entwicklungen zum Laser-strahlschweißen schwer schweißbarerWerkstoffe"

Studentenkongress im Rahmen derGroßen Schweißtechnischen Tagung, Dresden, 17. November 2008

[T31] B. Brenner, S. Bonß

"Hochleistungsdiodenlaser als Werk-zeug"

7. Workshop „Industrielle Anwendun-gen von Hochleistungsdiodenla-sern“,IWS Dresden, 24.-25. Juni 2008

[T32] B. Brenner, J. Hackius, J. Standfuß, D. Dittrich, B. Winderlich, J. Liebscher

"Laser Beam Welding of Aircraft Fuselage Structures"

27th International Congress on Applica-tions of Lasers and Electro Optics (ICA-LEO 2008), Temecula (CA), USA, 20.-23.Oktober 2008

[T33] B. Brenner, A. Jahn, J. Standfuß

"Improved Formability and Crash Perfor-mance of Laser-Welded Structures Madeof High Strength Multiphase-Steels"

9th European Automotive Laser Applica-tion Conference (EALA 2008), Bad Nau-heim, 31. Januar - 1. Februar 2008

[T34] B. Brenner, J. Standfuß, U. Stamm, D. Dittrich, A. Jahn, B. Winderlich

"Perspektiven für den Metallleichtbau inder Fahrzeug- und Luftfahrtindustriedurch fortgeschrittene Laserstrahl-schweißverfahren"

12. Dresdner Leichtbausymposium„Innovationsquelle Leichtbau“, Dresden,12.-14. Juni 2008

[T35] P. Bringmann, O. Rohr, J. Wehr, I. Jansen

"Cr+6-free Hybrid Coatings as PotentialPre-Treatment for Structural AdhesiveBonding"

Euradh 2008 / Adhesion ´08, 10th Inter-nat. Conf. Sci. & Techn. Adh. Adh.,Oxford, UK, 3.-5. September 2008

[T36] F. Brückner, D. Lepski, E. Beyer

"Simulation of Induction Assisted LaserCladding and Experimental Validation"

21th Meeting on Mathematical Model-ling of Materials Processing with Lasers,Igls, Österreich, 16.-18. Januar 2008


"Induktiv unterstütztes Laser-Pulver-Auf-tragsschweißen - Simulation und Experi-mente"

WLT Summer School 2008, Stuttgart, 3.März 2008


"Numerical and Experimental Investigati-on of Thermal Stresses and Distortionsin the Induction Assisted Laser Clad-ding"

3rd Pacific International Conference onApplication of Lasers and Optics (PICA-LO 2008), Peking, China, 16.-18. April2008


"Reduction of Thermally Induced Distor-tion in Laser Cladding"

2nd International Workshop on ThermalForming and Welding Distortion, Bre-men, 22.-23. April 2008

[T40] J. Chen, E. Louis, F. Bijkerk, C. J. Lee, R. Kunze, H. Schmidt, D. Schneider, R. Moors

"Characterization of EUV Induced Car -bon Films Using Laser-Generated Surfa-ce Acoustic Waves"

Diamond 2008, Sitges, Spain, 2008, 7.-11. September 2008

[T41] is I. Dani

"Atmospheric Pressure Plasmas for theManufacturing of Solar Cells"

New Technologies and Processes for thePhotovoltaic Industry Conference, Turin,November 2008

[T42] I. Dani, E. López, B. Dresler, D. Linaschke, H. Beese, V. Hopfe, S. Kaskel

"Atmospheric Pressure Plasma Processesfor Photovoltaics"

Nanofair 2008, Workshop energy, Dresden

[T43] I. Dani, E. Lopez, B. Dresler, J. Roch, G. Mäder, P. Grabau, V. Hopfe

"Kontinuierliche Prozessierung von kris -tallinen Si-Solarwafern durch plasma-chemisches Ätzen und Beschichten beiAtmosphärendruck"

XV. Erfahrungsaustausch "Oberflächen-technologie mit Plasma- und Ionen -strahl prozessen", Mühlleithen, 4.-6.März 2008


[T58] W. Grählert, H. Beese, P. Kaspersen, A. Bohman

"TraceScout - an Advanced SensorSystem for In-line Monitoring of SpecialGases in Semiconductor Industry"

1st European Conference on ProcessAnalytics and Control Technology,Frankfurt / M., 22.–25. April 2008

[T59] W. Grählert, M. Leistner, D. Linaschke, I. Dani

"Infrarotspektroskopische Charakterisie-rung photovoltaischer Produktionspro-zesse"

9. Wörlitzer Workshop Diagnostik &Prozesskontrolle bei der Herstellung vonSolarzellen, Wörlitz, 17. Juni 2008

[T60] W. Grählert, M. Leistner, M. Märcz, O. Jost, V. Hopfe, S. Kaskel

"In-situ Monitoring of the Synthesis ofSingle-wall Carbon Nanotubes (SWCNT)Using FT-NIR Spectroscopy"

Nanofair, Dresden, 11.-12.März 2008

[T61] W. Grimm, V. Weihnacht

"Super Hard Carbon Coatings Depositedby Pulsed DC-Arc-Process"

11th International Conference on PlasmaSurface Engineering, Garmisch-Parten-kirchen, 15.-19. September 2008

[T62] L. Haubold, M. Becker, T. Schuelke, C. Kleemann, H. Scheibe, C. Hinüber, R. Friedrichs, E. Hoeffing, M. Baumann

"JB-4-ta-C:X for Biomedical Implants"

SVC 2008, Chicago, USA, 19.-24. April2008

[T63] is T. Himmer, M. Lütke, L. Morgenthal

"Cutting Applications for High Brightness Lasers"

XIII International Conference on LaserOptics 2008, St. Petersburg, Russland,Juni 2008,

[T64] T. Himmer, M. Lütke, L. Morgenthal

"Potential des Remote-Laserstrahl-schneidens in der Fertigungstechnik"

DPS Kundentage 2008 – Faszination 4D,Dresden, Oktober 2008,

[T65] is T. Himmer, M. Lütke, L. Morgenthal, E. Beyer, C. Bratt

"Remote Cutting with High BrightnessLasers"

XXXII Conference on ProductionEngineering 2008, Novi Sad, SerbienSeptember 2008

[T51] B. Dresler, J. Roch, I. Dani, V. Hopfe, M. Heintze, R. Möller, M. Kirschmannn,J. Frenck, R. Dahl

"Silicon Nitride Produced by Atmosphe-ric Pressure Microwave PECVD"

23th European Photovoltaic Solar Energy Conference and Exhibition,Valencia, Spanien, September 2008

[T52] B. Dresler, J. Roch, I. Dani, V. Hopfe, B. Leupolt, A. Poruba, R. Barinka, M. Kirschmannn, J. Frenck

"Atmospheric Pressure MicrowavePECVD of Silicon Nitride Layers for Passivation of Solar Wafers"


[T53] P. Gawlitza, S. Braun, G. Dietrich, M. Menzel, S. Schädlich, A. Leson

"Ion Beam Sputtering of Multilayer X-Ray Optics"

Annual Meeting of Spie Optics & Photo-nics, San Diego, USA, 10.-14. August2008

[T54] P. Gawlitza, G. Dietrich, S. Braun, A. Leson

"Smoothing of Surface Roughness byIon Beam Deposition and Etching"

9th International Conference on the Phy-sics of X-ray Multilayer Structures Montana, USA, 3.-7. Februar 2008

[T55] L. Girdauskaite, S. Krzywinski, H. Rödel,R. Böhme, I. Jansen

"Possibilities for the Production of Com-plex Shaped Dry Textile Performs forHigh Quality Composites"

8th AUTEC Conference, Biella, Italien, 24.-26. Juni 2008

[T56] L. Girdauskaite, S. Krzywinski, H. Rödel,R. Böhme, I. Jansen

"Complex Shaped Dry Textile Preformsfor High Quality Composites"

2nd Aachen-Dresden International Textile Conference, Dresden, 4.-5.Dezember 2008

[T57] P. Grabau, G. Mäder, I. Dani, V. Hopfe

"Electrical Characterisation of a Linearlyextended Arc Discharge at AtmosphericPressure"


[T44] I. Dani, G. Mäder, J. Roch, P. Grabau, B. Dresler, D. Linaschke, S. Tschöcke, E. López, V. Hopfe

"Equipment for Atmospheric PressurePlasma Processing"

Eleventh International Conference onPlasma Surface Engineering, Garmisch,September 2008

[T45] C. Demuth, A. Mahrle, E. Beyer

"Partikelbasierte numerische Verfahrenzur Prozesssimulation in der Laser-materialbearbeitung – Potenzial, Metho-dik und Implementierung"

WLT-Summerschool, Stuttgart, 3. März 2008

[T46] G. Dietrich, P. Gawlitza, S. Braun, A. Leson

"Ionenstrahlsputtern von Kohlenstoff -Möglichkeiten und Grenzen bei der Her-stellung hochpräziser (Multi-) Schichten"

Erfahrungsaustausch "Oberflächentech-nologien mit Plasma- und Ionstrahlpro-zessen", Mühlleiten, 4.-6. März 2008

[T47] G. Dietrich, P. Gawlitza, S. Braun, A. Leson

"Reactive Nanometer Multilayers as Tailored Heat Sources for Joining Techniques"

4th Workshop on "Advanced Nanoma-terials", Wroclaw, Polen, 27.-28. Okto-ber 2008

[T48] D. Dittrich, E. Beyer, B. Brenner, J. Standfuß, B. Winderlich, J. Hackius

"Progress in Laser Beam Welding ofAircraft Fuselage Panels / Skin-Skin-Connections"

27th International Congress on Applica-tions of Lasers and Electro Optics (ICALEO 2008), Temecula (CA), USA,20.-23. Oktober 2008

[T49] D. Dittrich, B. Brenner, B. Winderlich, G. Kirchhoff, J. Hackius

"New Weld Seam Design for AdvancedJoining Techniques to Improve Safetyand to Reduce Structural Weight"

Aircraft Structural Design Conference,Liverpool, UK, 14.-16. Oktober 2008

[T50] D. Dittrich, B. Brenner, B. Winderlich, J. Standfuß, J. Liebscher, J. Hackius

"Laserstrahlschweißtechnologien fürinnovative integrale Rumpfschalen zivilerGroßraumflugzeuge"

Große Schweißtechnische Tagung, Dresden, 17.-19. September 2008




[T81] is A. Leson

"More Moore"

Gastvorlesung Universität OsakaOsaka, Japan, 23. Juli 2008

[T82] A. Leson

"Dünnschichttechnologie - Verfahren,Anwendungen, Perspektiven"

Fraunhofer Technologiezirkel: "Wirtschaftliches Potential der Nano-technologien", Würzburg, 15.-16. Oktober 2008

[T83] A. Leson

"Nanostructured Carbon Layers forWear Resistance and Friction Reduction"

2nd British-German Nanotech Forum"Commercialising Future Technologiesfor Energy and Automotive Applicati-ons", London, GB, 27. Oktober 2008

[T84] A. Leson, M. Leonhardt, C.-F. Meyer, H.-J. Scheibe, V. Weihnacht

"Deposition of Super Hard and Smoothta-C Films by Filtered Laser-Arc"

European Vacuum Coaters SymposiumAnzio, Italien, 29. September - 2. Okto-ber 2008

[T85] is A. Leson, M. Leonhardt, C.-F. Meyer, H.-J. Scheibe, V. Weihnacht

"Hard Nanostructured Carbon Coatings- Technology and Applications"

RusNanoTech'2008 NanotechnologyInternational Forum, Moskau, Russland, 3.-5. Dezember 2008

[T86] A. Leson, H.-J. Scheibe, V. Weihnacht

"Nanostructured Carbon Coatings -Technology and Applications"

MiNaT2008, Stuttgart, 8. Oktober 2008

[T87] S. Lipfert, S. Braun, P. Gawlitza, J. Schmidt, A. Leson

"Inner Coating of EUV Collector Shells"


[T88] S. Lipfert, P. Gawlitza, S. Braun, A. Leson

"Application of Large Ion Beam Techno-logy for Optical Coatings"


[T66] V. Hopfe, I. Dani, E. López, B. Dresler,M. Heintze, R. Möller, H. Wanka, A. Poruba, R. Barinka, M. Kirschmannn,J. Frenck

"Atmospheric Pressure Plasmas for Coating and Etching of Solar Wafers"

11th International Conference on PlasmaSurface Engineering, Garmisch-Parten-kirchen,15.-19. September 2008

[T67] is V. Hopfe, D. W. Sheel

"Atmospheric Pressure Plasmas forCrystalline Silicon Photovoltaics"

51st SVC Annual Technical Conference,Chicago, 19.-24. April 2008

[T68] is V. Hopfe, D. W. Sheel, R. Moeller

"Nanostructured c-Si Photovoltaic Cellsby Atmospheric Pressure Plasma Proces-sing"

International Conference on FunctionalNanocoatings, Budapest, 30. März -2. April 2008

[T69] Š. Houdková, F. Zahálka, M. Kašparová,L.-M. Berger

"Tribological Behaviour of ThermallySprayed Coatings at Elevated Temperatures"

International Thermal Spray Conference& Exhibition, Maastricht, Niederlande,2.-4. Juni 2008,

[T70] A. Jahn, M. Krätzsch, B. Brenner

"Laserstrahlschweißen hochfester Fein-kornbaustähle mit werkstoffangepassterTemperaturführung"

Große Schweißtechnische Tagung, Dresden, 17.-19. September 2008

[T71] A. Jahn, M. Krätzsch, B. Brenner

"Induction Assisted Laser Beam Weldingof HSLA Steel Sheets"

International Scientific Colloquium"Modelling for Electromagnetic Proces-sing", Hannover, 27.-29. Oktober 2008

[T72] I. Jansen, J.-S. Pap, R. Rechner

"8. Kolloquium Gemeinsame Forschungin der Klebtechnik"

Frankfurt, 26.-27. Februar 2008

[T73] I. Jansen, R. Rechner

"Einsatz des Diodenlasers zur Kantenlei-mung"

7. Workshop "Industrielle Anwendungvon Hochleistungsdiodenlasern", IWSDresden, 24.-25. Juni 2008,

[T74] J. Kaspar, J. Bretschneider, S. Bonß, B. Winderlich, B. Brenner

"Laser Nitriding: A Promising Way toImprove the Cavitation Erosion Resi-stance of Components Made of Titani-um Alloys"

Symp. On Friction, Wear and Wear Pro-tection, Aachen, 9.-11. April 2008

[T75] A. Klotzbach

"Introduction to Remote Welding / Cut-ting Systems"


[T76] A. Klotzbach, M. Leminski, J. Standfuß,R. Schedewy, A. Mahrle, F. Brückner

"Zukünftige Industrieanwendungen fürbrillante Laserquellen und deren Qualifi-zierung unter Nutzung der Strahl-diagnostik"

3. Primes Workshop, Pfungstadt, 9.-10. September 2008

[T77] S. Kühn, J. Hannweber, B. Brenner,E. Beyer

"A Novel Active Laser Safety Shield"


[T78] M. Leistner, M. Märcz, W. Grählert, V. Hopfe, O. Jost, S. Kaskel

"In-situ Monitoring of Single-Wall Car -bon Nanotubes (SWCNT) SynthesisUsing FT-NIR Spectroscopy"

1st European Conference on ProcessAnalytics and Control Technology(EUROPACT), Frankfurt / M., 22.–25.April 2008

[T79] D. Lepski, F. Brückner

"The Physics of Laser Cladding"

21. Meeting on Mathematical Modelingof Materials Processing with Lasers, Igls,Österreich, Januar 2008

[T80] is A. Leson

"Current Research and TechnologyTransfer at the Fraunhofer Institute forMaterial and Beam Technology"

Center of Condensed Matter of theMexican Autonomous National Universi-ty, Ensenada, Mexiko, 30. April 2008

[T89] E. López, I. Dani, V. Hopfe, M. Heintze,R. Möller, H. Wanka, H. Nußbaumer, R. Dahl, A. Poruba, R. Barinka, M. Kirschmann, J. Frenck

"Plasma Enhanced Chemical Etching atAtmospheric Pressure for Crystalline Silicon Wafer Processing"

23th European Photovoltaic Solar EnergyConference and Exhibition, Valencia,Spanien, September 2008

[T90] E. López, B. Dresler, G. Mäder, S. Krause, I. Dani, V. Hopfe, M. Heintze,R. Möller, H. Wanka, M. Kirschmann, J. Frenck, A. Poruba, R. Barinka, R. Dahl,H. Nussbaumer

"Plasma Enhanced CVD and PlasmaChemical Etching at Atmospheric Pressure for Continuous Processing ofCrystalline Silicon Solar Wafers"

51st SVC Annual Technical Conference,Chicago, USA, 19.-24. April 2008

[T91] E. López, D. Linaschke, H. Beese, G. Mäder, I. Dani, V. Hopfe, M. Kirschmann, J. Frenck

"Plasma Chemical Etching for In-line c-SiSolar Cell Processing at AtmosphericPressure"


[T92] M. Lütke, A. Mahrle, T. Himmer, L. Morgenthal, E. Beyer

"Remote-Cutting – A Smart SolutionUsing the Advantages of High Brightness Lasers"


[T93] A. Mahrle, F. Bartels, E. Beyer

"Theoretical Aspects of the Process Efficiency in Laser Beam Cutting withFibre Lasers"


[T94] A. Mahrle, E. Beyer

"Derivation of Optimal Processing Para-meters for Conduction Mode Laserbeam Welds by Simulation"

3rd Pacific International Conference onApplications of Lasers and Optics,Peking, China, 16.-18., April 2008(Postervortrag)

[T95] C.-F. Meyer, H.-J. Scheibe

"Filtered Laser-Arc: A New Technologyfor Deposition of Smooth ta-C Films"

ICMCTF 2008, San Diego, USA, 28. April – 2. Mai 2008

[T96] S. Nowotny

"Industrielle Lösungen für das Laser-strahl-Auftragschweißen"

TAW-Symposium Thermisches Beschich-ten mit laserbasierten Fertigungsverfah-ren, IWS Dresden, 12.-13. Februar 2008

[T97] S. Nowotny, S. Scharek, A. Schmidt, F. Kempe

"Systemtechnische Lösungen für die Pra-xis des Auftragschweißens mit Diodenla-sern"

7. Workshop "Industrielle Anwendun-gen von Hochleistungsdiodenlasern“,IWS Dresden, 24.-25. Juni 2008

[T98] S. Nowotny, S. Scharek, S. Thieme, R.A. Gnann

"Flexilas - eine neue Dimension derLaser-Materialbearbeitung mit Zusatz-werkstoffen"

Karlsruher Arbeitsgespräche Produk -tionsforschung 2008, Karlsruhe, 11.-12.März 2008

[T99] S. Nowotny, S. Scharek, S. Thieme, R.A. Gnann

"Flexilas: Laser-Auftragschweißen mitzentrischer Drahtzufuhr"

Die Verbindungs Spezialisten, GroßeSchweißtechnische Tagung, Dresden,17.-19. September 2008

[T100] L. Prager , P. Marsik, J. W. Gerlach, M. R. Baklanov, S. Naumov, L. Pistol, D. Schneider, L. Wennrich, P. Verdonck,M. R. Buchmeise

"Effect of Pressure on Efficiency of UVCuring of CVD-Derived Low-K Materialat Different Wavelengths"

European Workshop on Materials forAdvanced Metallization (MAM 2008),Dresden, 2.-5. März 2008

[T101] R. Rechner, I. Jansen

"Laservorbehandlung von Leichtmetallenvor dem Kleben"

6. Praxisseminar Kleben, Jena, 12. Februar 2008

[T102] R. Schedewy, E. Beyer, B. Brenner, A. Grimm, D. Dittrich, J. Standfuß

"Laser Beam Welding of High StiffnessLight Weight Structures Generated byScanned Fiber Laser"

27th International Congress on Applica-tions of Lasers and Electro Optics (ICALEO 2008), Temecula (CA), USA, 20.-23. Oktober 2008

[T103] H.-J. Scheibe, A. Leson, V. Weihnacht

"Pulsed Arc Deposition of Modified ta-CFilms, Tribological Properties and Appli-cations"

HIPIMS Days, Venlo, Niederlande, 7.-8. Juli 2008

[T104] H.-J. Scheibe, V. Weihnacht, A. Leson

"Friction and Wear Behaviour of Modi-fied ta-C Films"

ICMCTF 2008, San Diego, USA, 28. April - 2. Mai 2008

[T105] D. Schneider, A. Leson

"Evaluating Thin Films and Material Sur-faces by the Surface Acoustic WaveTechnique LAwave"

MicroCar 2008, Leipzig, 27. Februar2008

[T106] C. C. Stahr, L.-M. Berger, M. Herrmann,D. Deska

"Corrosion of Alumina-Based Coatings"

International Thermal Spray Conference& Exhibition, 2.-4. Juni 2008, Maastricht, Niederlande

[T107] C. C. Stahr, L.-M. Berger, M. Herrmann,D. Deska, F.-L. Toma


11. Werkstofftechnischen Kolloquium inChemnitz, 1.-2. Oktober 2008

[T108] C. C. Stahr, L.-M. Berger, S. Thiele, S. Saaro

"Thermally Sprayed TiO2-Cr2O3 Coatingswith Multifunctional Properties"


[T109] is C. C. Stahr, L.-M. Berger, F.-L. Toma

"Keramische Schichten im SystemAl2O3-Cr2O3-TiO2 – ausgewählte Entwicklungstendenzen"

4. GTV Kolloquium Thermisches Sprit-zen, Luckenbach, 5. September 2008,





[T110] J. Standfuß, U. Stamm, G. Göbel, S. Schrauber, B. Brenner

"Future Powertrain Welding ApplicationsDriven by Fiber Lasers"

Automotive Laser Application Workshop2008 (ALAW 2008), Plymouth (MI), USA, 13.-15. Mai 2008

[T111] T. Stucky, V. Weihnacht, S. Bräunling

"Potential von ta-C-Schichten für dieTrockenumformung"

3. Workshop "Kohlenstoffschichten -tribologische Eigenschaften und Verfah-ren zu ihrer Herstellung", Dortmund, 4. Juni 2008

[T112] A. Techel

"Lasersysteme und Photovoltaik – eineEinführung"

Lasersysteme und Photovoltaik, Fellbach/Stuttgart, 22.-23. April 2008

[T113] A. Techel

"Technologievorsprung durch Laser- undOberflächentechnik"

Fokus Technologie, Stuttgart, 30.-31. Oktober 2008

[T114] F.-L. Toma, L.-M. Berger, D. Jacquet,D. Wicky, I. Villaluenga, Y.R. de Miguel,J.S. Lindeløv

"Comparative Study on the Photocataly-tic Behaviour of Titanium Oxide ThermalSprayed Coatings from Powders andSuspensions"

2nd International Workshop on Suspen-sion and Solution Thermaly Spraying,Tours, 5.-7. Juni 2008

[T115] F.-L. Toma, L.-M. Berger, D. Jacquet, D. Wicky , I. Villaluenga, Y. R. deMiguel, J. S. Lindeløv

"Vergleichende Untersuchungen zu denphotokatalytischen Eigenschaften vonthermisch gespritzten Titanoxidschichtenaus Pulvern und Suspensionen"

11. Werkstofftechnischen Kolloquium,Chemnitz, 1.-2. Oktober 2008

[T116] F.-L. Toma, L.-M. Berger, T. Naumann,S. Langner

"Characterisation of Ceramic Nanostruc-tured Coatings Prepared by ThermalSpraying of Suspensions"


[T117] S. Tschöcke, I. Dani, V. Hopfe

"Kontinuierliche Großflächenbeschich-tung von transparenten, kratzbeständi-gen SiO2-Schichten mittels DC-Arc-PECVD bei Atmosphärendruck"

4. Thüringer Grenz- und Oberflächen -tage, Jena, September 2008

[T118] V. Weihnacht

"Nanostructured Carbon Coatings forWear Resistance and Friction Reduction"

Seminars and Lab tours "Nanotechnolo-gies for Energy and Energy Efficiency"Dresden, 13. März 2008

[T119] V. Weihnacht

"Mechanisch-tribologische Anpassungdurch ta-S-basierende Schichtsysteme"

3. Workshop "Kohlenstoffschichten -tribologische Eigenschaften und Verfahren zu ihrer Herstellung", Dortmund, 4. Juni 2008

[T120] V. Weihnacht

"Amorphe Kohlenstoffschichten undderen tribologische Eigenschaften"

Institutskolloquium MPA TU DarmstadtDarmstadt, 19. Juni 2008

[T121] V. Weihnacht

"Diamantartige Kohlenstoffschichten mitPotenzial zur Trocken-Blechumformung"

1. Workshop "Oberflächen für die Pro-duktion - dünne Schichten in geschmier-ten und ungeschmierten Systemen",Dresden, 17. Oktober 2008

[T122] V. Weihnacht, A. Brückner


Seminar Hanser-Verlag "FunktionaleSchichten", Fellbach, 11.-12. März 2008

[T123] V. Weihnacht, A. Brückner


Workshop "Friction, Wear and Wearprotection", Aachen, 9.-11. April 2008

[T124] V. Weihnacht, A. Brückner, S. Bräunling

"Diamantartige Kohlenstoffschichten mitPotenzial zur Trockenumformung"

EFB-Kolloquium, Dresden, 3.-4. April 2008

[T125] V. Weihnacht, H.-J. Scheibe

"Friction and Wear Behaviour of Modi-fied Diamondlike Carbon Films"

16th International Colloquium Tribology,Stuttgart, 15.-17. Januar 2008

[T126] V. Weihnacht, H.-J. Scheibe, A. Leson

"ta-C and Modified ta-C:X Films forDemanding Tribological Applications"


[T127] B. Weller, I. Jansen, S. Tasche

"Adhesive Joints With Acrylates in GlassStructures"

Euradh 2008 / Adhesion ´08, 10th

Internat. Conf. Sci. & Techn. Adh.,Oxford, UK, 3.-5. September 2008

[T128] S. Winkler, S. Braun, P. Gawlitza, D. C. Meyer

"Fabrication and Characterization ofMultilayered Thermal Barrier Coatings"


[T129] O. Zimmer

"Hard Coatings Thicker Than 20 Microns- an Experimental Study"

HIPIMS Days, Venlo, Niederlande, 7.-8. Juli 2008

[T130] O. Zimmer; F. Kaulfuß

"Hard Coatings with Elevated FilmThickness Prepared by PVD"



Address:

Fraunhofer Institute forMaterial and Beam Technology IWS(Fraunhofer-Institut für Werkstoff- und Strahltechnik IWS)

Contact: Dr. Ralf Jäckel

Winterbergstraße 28 01277 Dresden

phone:+49 (0) 351 2583 444 fax: +49 (0) 351 2583 300 e-mail: [email protected]

website: www.iws.fraunhofer.de

If you would like to receive more in -formation, please tick correspondingitems below and send a copy of thepage by mail or fax to the IWS.

I am interested in:

- The brochure "Germany’s Elite-Institutes - Fraunhofer IWSDresden" (in German)

- The brochure "Germany’s Elite-Institutes - Fraunhofer IWSDresden" (in English)

- The brochure "One-Stop Solutions"(in German)

- The brochure "One-Stop Solutions"(in English)

- Annual Report 2006 (in English)

- Annual Report 2007 (in English)

- Additional copy of the 2008 Annu-al Report

Please send me material about thefollowing processes and methods:

Area PVD- and nanotechnology

- Multilayers for x-ray optical applica-tions

- Diamor® - Superhard amorphouscarbon films on tools for machiningand forming of metals and poly-mers

- Diamor® - Superhard amorphouscarbon films for components ofpackaging and food processingmachines

- Laser-acoustic technique for testingcoatings and material surfacesLAwave®

- Laser-Arc module for the deposi-tion of super hard amorphous car-bon coatings

Area CVD thin film technology

- FTIR spectroscopy for CVD diagnostics

- Optical spectroscopy of surfacesand films

Area thermal coating

- COAXn: powder nozzles for laserprecision built-up welding

- Laser rapid prototyping - a processfor the fast manufacturing of func-tional samples

- Rapid prototyping of metallic partsthrough laser liquid phase sinteringof composite powders

- Advanced coating solutions: Thermal Spray

Area joining and surface treatment

- Laser beam welding and hybridwelding processes

- Laser beam welding with highpower diode lasers

- Inductively supported laser materials processing

- Technological developments for theaerospace industry

- Materials characterization for newprocesses and products

- GEOPT - Software for laser beamhardening

Area system engineering / laserablation and cutting

- lasertronic® - Systems made byFraunhofer IWS Dresden

- lasertronic® - High-speed beamscanning for laser beam welding

- Shape precision high-speed lasercutting

- Laser beam ablation of thin surfacelayers

- Patina excavating with laser beam

- Micro cutting and drilling withultraviolet light

- Microstructuring of ceramics withexcimer lasers

- Slip-free modification of naturalstone surfaces

Information service


Address and directions

Institute address:

Fraunhofer-Institut für Werkstoff- und Strahltechnik (Fraunhofer Institute for Material and Beam Technology)

Winterbergstr. 28 01277 Dresden, Germany

phone: +49 (0) 351-2583-324 fax: +49 (0) 351-2583-300 [email protected] www.iws.fraunhofer.de

Directions:

by car (from Autobahn / Highway)

- take Autobahn A4 or A13 to inter -section Dresden-West, follow newAutobahn A17 to exit Südvorstadt /Zentrum

- follow road B170 in directionStadtzentrum (city center) to Pirnaischer Platz (about 6 km)

- at Pirnaischer Platz turn righttowards "Gruna / VW-Manufaktur"

- continue straight until the end of the"Großer Garten" (Great Garden) andthen turn right onto Karcherallee

- at the next traffic light turn left ontoWinterbergstraße and continuestraight until IWS

by railway and tram

- from Dresden main railway stationtake line #10 to Straßburger Platz

- change to line #1 or #2 heading outfrom the city (toward Klein zschach -witz or Prohlis); exit at Zwinglistraßestop

- 10 minutes to walk from there (inthe direction of Grunaer Weg) orone station by bus # 61 (in the direction Löbtau)

by air plane

- from Airport Dresden-Klotzsche witha taxi to Winterbergstraße 28 (distance is approximately 7 miles or10 km)

- or with public transportation (shuttletrain) to the main railway station(Hauptbahnhof), and continue withthe tram


Editorial notes

Editorial staff: Dr. Ralf Jäckel Karin JuchDr. Anja Techel

Coordination / editing: Karin Juch Dr. Ralf Jäckel

Photos: page 6 (top l. pic.): Fraunhofer IWS / TU Wrocławpage 7 (top m. pic): teamtechnik Maschinen und

Anlagen GmbH Freibergpage 28 (top): EMAG Lasertech GmbH Salach /

Heubachall other pictures: Fraunhofer IWS Dresden

Quotations: The quotations are translated faithfully to their meanings.

© Fraunhofer-Institut für Werkstoff- und Strahltechnik IWS Dresden 2009

Reprints require permission of the editor.

annual report 2008 · coated ball valves in 2008 the results of a joint research project with the...

Documents