Lightweight technologies
Lightweight technologies for the mobility of the future
Lightweight construction is a key aspect of the mobility of the future. In the Metal Forming Division, one project is dedicated to the hybridization of materials, either by modifying semi-finished products or by joining them with state-of-the-art welding equipment. This improves efficiency and sustainability in parts production.
New paradigms, the Green Deal and the principles of the circular economy are increasing the relevance of lightweight construction technologies in various mobility applications of the future. If implemented correctly, lightweight construction can become one of the key technologies of the circular economy and thus also gain importance in political perception.
A green perspective for the future
Lightweight structures can reduce the weight of vehicles and thus increase their range. In addition, lightweight production methods require less material than conventional production methods. This not only increases efficiency, but also reduces CO2 emissions.
Lightweight construction is a key interdisciplinary technology for sustainability
Karl M. Radlmayr, Senior Vice President R&D in the Metal Forming Division
Hybrid7 AI project: efficiency through intelligent connection solutions
The Metal Forming Division is currently running an exciting project on the subject of hybridization, which focuses on the research and development of a new approach to parts production. The Hybrid7Al project involves the modification of semi-finished products (sheets, extruded profiles, roll-formed profiles, etc.) using wire-DED and the joining/modification of different aluminum grades using state-of-the-art welding equipment.
The project focuses on high-strength but difficult-to-weld 7xxx aluminum alloys and their combination with modern 6xxx alloys. The areas of application are automotive, rail and aviation.
Innovative application processes for resource-saving component production
The use of innovative, wire-based direct deposition processes (wire-DED), also known as wire arc additive manufacturing, offers two options for the production of parts to keep energy efficiency high and thus the carbon footprint low:
- Production of the final component by direct wire-based additive manufacturing.
- Additional reinforcement of conventionally manufactured components with wire-DED
In both cases, the buy-to-fly ratio (BtF) is improved by avoiding machining scrap, which is generated, for example, by machining processes.
Sustainable added value in many respects
Other advantages include the increased production flexibility of small series structures, the ability to manufacture complex geometries with integrated functions and the decentralized production of parts, which reduces the carbon footprint by saving on transport.