running projects

Project-No. 01|F0079AE | EFDS-Nr. IGF-LEIT-24-09

period: 01.07.2025 – 31.12.2027

research institute: Fraunhofer Institut für Solare Energiesysteme ISE

abstract

The general research objective of Laser-VIG is to establish an innovative production technology for manufacturing the next generation of insulating glass. The focus is on optimising the thermal insulation effect, minimising energy consumption in production, good recyclability and a low CO2 footprint. The technological approach of vacuum insulation glass (VIG) is being pursued. A new, highly efficient approach is used for the edge seal, which is the critical component of VIG. Solderable thin layers are applied to the edge of the panes. The edge seal is then joined with metallic solder using localised laser heating. Due to the low joining temperature, the process can be realised with a high throughput, which enables cost-effective production. In addition, the safety glass properties of thermally toughened panes are retained. These two advantages should lead to broad market acceptance of VIG.
In this project, these developments are to be driven forward in close coordination with the project support committee (PA). The PA covers the entire value chain of VIG production and utilisation. The technologies used – vacuum technology, thin-film technology, laser joining and optical measurement technology – “fit” very well with the existing technology lines of medium-sized companies. The result is an ideal field for the expansion and development of existing business areas. For the globally strong German glass processing and finishing industry and the internationally positioned plant manufacturers (SMEs), this production technology expands the traditionally successful business model.

Project-No. 01|F23642N | EFDS-Nr. IGF-22-01

period: 01.07.2025 – 31.12.2027

research institution

Leibniz-Institut für Festkörper- und Werkstoffforschung Dresden e.V.
Technische Universität Chemnitz, Institut für Werkzeugmaschinen und Produktionsprozesse
Technische Universität Chemnitz – Zentrum für Mikro- und Nanotechnologien (ZfM)

abstract

Microelectronic and micromechanical components (MEMS) are essential in almost every industrial sector. Wafer bonding enables the encapsulation of MEMS for 3D integration. The entire substrate stack is exposed to very high global temperatures (= 550 °C) and joining pressures (= 100 MPa). The heating and cooling processes are time-consuming and can lead to thermomechanical stresses and damage. Accordingly, MEMS packaging is often the most expensive, time-consuming and energy-intensive sub-process in MEMS production. The aim of the InduAlloy project is to develop an inductive wafer bonding process based on process chain and CMOS-compatible, Al-based eutectic alloys or metallic glasses as joining additives for wafer bonding. The eutectic multi-material systems allow the oxide layer to be destabilised and the melting temperature and process time to be reduced. The use of metallic glasses as joining materials enables joining with electrically conductive, amorphous intermediate bond layers to increase long-term stability and reliability.
With the alloys developed, the inductive heating of the bond frames is to be optimised and the potential of inductive wafer bonding fully exploited. The process-related reduction in process times and thermal load on the components enables new wafer construction concepts, higher integration densities and significant energy savings. InduAlloy will enable the numerous German SMEs from the value-added stages of primary materials, sputtering process and structuring, components, systems and applications in particular to access the personnel and system-related research capacities (e.g. alloy development, experimental technology, high-frequency technology, simulation) for the development of interdisciplinary problems from materials technology, electrical process technology and microtechnology, for which they do not have their own capacities.

Project-No. 01|F23675N | EFDS-Nr. IGF-23-04

period: 01.07.2025 – 30.06.2027

research institute: Fraunhofer-Institut für Fertigungstechnik und Angewandte Materialforschung IFAM

abstract

Silicone is indispensable for applications in medical technology due to its permanent flexibility and physiological harmlessness, but requires surface treatment due to its high surface stickiness and susceptibility to dirt. Industrially, gas phase fluorination of silicone components is currently used for this purpose, which urgently needs to be replaced due to increasing legal restrictions (PFAS). This research project aims to develop sustainable alternatives for industrial applications that can be used to produce low-friction and dirt-repellent silicones. The desired surface modification is to be achieved on the one hand by means of VUV-radiation-rich low-pressure plasmas, using the approach of utilising the radiation effect alone, and on the other hand by depositing plasma-polymer layers that are gradually adapted to the silicone substrate. In addition to processes for flat material, specific solutions for three-dimensional structures (moulded parts) are to be developed.
During the course of the project, not only will the refined silicones be thoroughly characterised on the material side, but the suitability and cost-effectiveness of the processes will also be evaluated, particularly for potential applications in medical technology. This will enable SMEs along the entire value chain (silicone manufacturers and processors, users, plant manufacturers, contract coaters) to benefit. The new product quality (permanently clean surfaces, low friction, longer service life) should enable manufacturers of silicone products to expand their position on the market and open up further areas of application (e.g. automotive). For the first time, SMEs in the silicone processing or contract coating sectors that already have plasma systems will be able to carry out the silicone finishing work themselves, which is currently carried out externally in the form of gas phase fluorination.

Project-No. 01|F23381N | EFDS-Nr. IGF-22-05

Duration: 01.09.2024 – 31.08.2026

research institution

RWTH Aachen, Institut für Oberflächentechnik

abstract

According to the current state of research and development, there are no self-lubricating PVD coatings for applications at T ≥ 500 °C that are based on a solid lubricant with a layer lattice structure. However, such a coating could lead to an increase in performance in applications such as machining and hot forming.
TiBN coatings with the solid lubricant hexagonal boron nitride (h-BN), which is oxidation-resistant up to T = 900 °C, are very promising. TiBN coatings are already being used in machining and hot forming. However, the TiBN coatings available on the market have so far only been produced using chemical vapour deposition at process temperatures of 900 °C ≤ T ≤ 1,100 °C. With hot forming tools, these high temperatures lead to component distortion and cost-intensive reworking. The use of physical vapour deposition (PVD) has great potential. The technology variant of pulsed arc PVD is very promising.
The research objective is the production of self-lubricating TiBN coatings with h-BN content using pulsed arc PVD technology to reduce friction in tribological applications in the high temperature range of 500 °C ≤ T ≤ 800 °C. The desired results are the identification of suitable process windows and layer architectures for the production of TiBN coatings. Furthermore, the extent to which the performance of the self-lubricating TiBN coatings can be increased with regard to their tribological use in machining and hot forming will be investigated. The expected results show a very high innovation potential. In addition, there is an extremely broad
user group across several economic sectors, which are predominantly dominated by SMEs. These include thin-film technology with its contract coaters, mechanical and plant engineering and their suppliers, target manufacturers and, last but not least, users in machining and hot forming.

Project-No. F23226N | EFDS-No. IGF-21-10

project period: 01.07.2024 – 30.06.2026

research institution

RWTH Aachen, Institut für Oberflächentechnik

abstract

Physical vapor deposition (PVD) is used with a steadily growing market share for wear protection on components and tools in order to increase service life and performance. Residual stresses are of particular importance here. In industrial sputtering processes, such as High Power Pulsed Magnetron Sputtering (HPPMS), process gases such as argon are used to extract atoms or ions of the layer-forming material from a target material. In addition to the target, the argon ions, some of which are highly energetic, also strike the growing coating through the applied bias voltage. This results in the implantation of these ions into the coating and thus an influence on the residual stresses. This can affect the mechanical properties and therefore the cutting performance of the tools. During the pulse time of an HPPMS process, the concentration of argon ions in the coating plasma changes. In the proposed research project, a positive bias pulse is synchronized with the HPPMS cathode pulse in such a way that the argon implantation and thus the residual stress state can be controlled. In order to analyze the influence of the positive bias pulse on the plasma properties such as the composition of the coating plasma and the ion energy, plasma diagnostics such as optical emission spectroscopy, mass spectrometry and counter-field analysis are used. The results of the plasma analyses are correlated with the layer properties of the coating, such as the residual stresses and the chemical composition. The research project will extend conventional HPPMS process control in order to increase the cutting performance of tools by adjusting the residual stress state. SMEs in the field of industrial power supplies, PVD system manufacturers, manufacturers of plasma diagnostics and cutting tools will therefore benefit from the results.

Project-No. F23260N | EFDS-Nr. IGF-22-03

project period: 01.03.2024 – 31.08.2026

research institution

Technische Universität Darmstadt
Technische Universität Braunschweig

abstract

The use of austenitic stainless and acid-resistant (RS) steels for bipolar plates in fuel cells and hydrogen electrolysis offers enormous potential for cost and volume savings as well as for increasing efficiency compared to graphite-based bipolar plates and at the same time represents an economical alternative to other titanium- or nickel-based materials. However, the natural passive layer of RS steels requires additional surface treatment. Surface modification using plasma diffusion processes would represent an alternative to PVD / CVD-based processes, particularly in terms of coating costs, material consumption and energy balance, and would increase sustainability.
The aim of the proposed project is to develop plasma diffusion processes to improve the performance and cost efficiency of fuel cell components.

The intended results hold the following innovation potential:

– Scientific and technical basis for the production of robust and inexpensive bipolar plates
– Identification of process parameter-property interactions
– Economic advantages through optimization of material selection, treatment parameters and production costs
– Consideration of the flow-dynamic, thermal and electrical stress collective under
practical conditions and research into degradation mechanisms
– Ecological advantages through ensuring or increasing the component service life

Thus, the benefits and significance of the project are very high, especially for SMEs. The potential user group of the research project concerns the following economic sectors (according to the IGF guidelines): 24 (metal production and processing); 28 (mechanical engineering), 35 (energy generation), 29 (manufacture of motor vehicles and motor vehicle parts) and 30 (other vehicle construction).

AiF-Nr. | EFDS-Nr. IGF-22/04