Institute of Vehicle Concepts - Material and Process Applications for Road and Rail Vehicles

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Active energy absorber

For some years now, vehicle manufacturers have been expanding their model range with a variety of different vehicles and derivatives. Due to the applicable approval standards, vehicle manufacturers design their body structures mainly in terms of vehicle mass or kinetic energy. Smaller vehicles may therefore be at a disadvantage compared to heavier vehicles, as they generally have less mass and shorter front weighbridges. Conventional side members designed for crease buckling do not offer the possibility of active adaptation to different accident scenarios.

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FoAIm - Coupling complex, cross-scale foam characteristics using artificial intelligence methods

The use of machine learning (ML) offers enormous potential to accelerate the characterisation of material properties and thereby greatly facilitate the use of new materials in future vehicles. The aim of this project is to bridge the gap between the micro-structural design and the mechanical properties by coupling experimental and simulative data, and subsequently to significantly reduce the time and effort required for characterisation when transferring the product to the application.

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HyEnd-Wood ++ Hybridized Engineered Wood ++

Wood-based lightweight materials are to become an integral part of the design of structural and semi-structural vehicle components in order to achieve cost-efficient and CO2 reducing lightweight construction in the future. For this purpose, the partners have launched the HyEnd-Wood project (Hybridized Engineered Wood - development of a hybridised wood-based material for structural components by forming a strand-based composite semi-finished product).

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	Characterisation of core materials and design method for sandwich structures Fundamental research on core materials for investigating and developing a method for applying sandwich structures in load-bearing vehicle components
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For(s)tschritt ++ Wood-based material systems for vehicle structure applications ++

In the "For(s)tschritt" project nine industrial and scientific partners have joined forces to exploit the lightweight construction potential of wood in composite materials with metallic materials in load-bearing structures. Because of this, in addition to the characterisation of wood-based multi-material systems for the creation of simulation models, structurally relevant assemblies for rail and road vehicles were manufactured and used as demonstrators.

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	FUMAS - Function-integrated lightweight magnesium construction on car seat structures The FUMAS project realised a weight reduction of a seat structure by using extruded magnesium and a novel process route in manufacturing. A lighter backrest structure was conceived, designed and evaluated.
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	International Cooperations Today’s challenges for lightweight construction are very similar worldwide. This encourages us, the research field WVG, to cooperate with other automotive regions of the world. The aim is to research and develop together new technologies to combine structural lightweight construction with safety, sustainability and cost-effectiveness.
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KraSchwing - Optimisation of load transmission in fiber composite structures subject to vibration stress

Within the joint research project KraSchwing, DLR researched innovative approaches for joining in hybrid structures. The introduction of elastomer layers into laminates as well as rosettes for reinforcing the reveal of screw connections, which are implemented by using wet-wound, pre-impregnated loops, were considered as novel options for adapting joints. New approaches for connections in hybrid structures were explored and compared with traditional approaches.

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	NGC - Adaptive crash structure The DLR Institute of Vehicle Concepts investigates adaptive crash structures which allow simple adaption of crash properties without the necessity of expensive modifications to the vehicle structure.
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NGC – Joining Technologies

Choosing joining technologies for multi-material structures two essential challenges have been identified in preceding research work. Firstly, a suitable methodological approach for the (automated) choice of joining configurations still has to be worked at, to achieve the optimal load transfer at given mechanical stress. Secondly, it is necessary to be able to assess the influence of aging on mechanical properties in a quantitative way, with special focus on corrosion processes.

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PuVerSand* – Spot joining of structurally load-bearing sandwich-structures

Sandwich structures offer great potential as load-bearing vehicle components. This fact has already been demonstrated in the DLR large-scale project “Next Generation Car ”. Despite their significant weight reduction potential, application and implementation in series production remains challenging for sandwich structures. Currently, the lack of suitable joining concepts is one of the main reasons hindering these innovative composite materials to be applied in industrial largescale production.

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SuMatHrA - Substitution of conventional materials for lightweight construction by wood hybrids based on Albasia

In the transport sector and especially in electromobility, lightweight construction continues to play a central role in increasing efficiency. However, the lightweight materials currently used, with their high CO2 footprint during production, often conflict with sustainability and resource conservation. One way to resolve this conflict is to use sustainable lightweight materials, such as wood.

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Kontakt WVG

Dr.-Ing. Elmar Beeh
Institute of Vehicle Concepts
Material and Process Applications for Road and Rail Vehicles
Stuttgart
Tel.: +49 711 6862 8311
Fax: +49 711 6862-258

Active energy absorber

FoAIm - Coupling complex, cross-scale foam characteristics using artificial intelligence methods

HyEnd-Wood ++ Hybridized Engineered Wood ++

Characterisation of core materials and design method for sandwich structures

For(s)tschritt ++ Wood-based material systems for vehicle structure applications ++

FUMAS - Function-integrated lightweight magnesium construction on car seat structures

International Cooperations

KraSchwing - Optimisation of load transmission in fiber composite structures subject to vibration stress

NGC - Adaptive crash structure

NGC – Joining Technologies

PuVerSand* – Spot joining of structurally load-bearing sandwich-structures

SuMatHrA - Substitution of conventional materials for lightweight construction by wood hybrids based on Albasia