TRR 375:  Multi-functional high performance components made from hybrid porous materials

• Subject Area: Materials Science and Engineering ; Computer Science, Systems and Electrical Engineering ; Mechanical and Industrial Engineering
• Term: since 2024
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 511263698

The central scientific objective of CRC/TRR 375 is to establish a new class of components: multifunctional high-performance components made of hybrid porous (HyPo) materials. HyPo-components are made by combining different materials featuring a locally varying density, e.g. in the form of pores and fulfil more than one function at a time. Their functional performance is closely linked to the material or material state and the resulting material properties. Due to their high technical relevance and good recyclability, the CRC/TRR will focus its research on metallic materials. By locally varying the density, HyPo-components achieve significant weight reduction in low-stress areas, resulting in improved efficiency, particularly under dynamic stress. The hybrid material approach offers additional benefits by allowing the selective adjustment of material-specific properties. For example, high-stress areas can be reinforced for increased strength, while areas subject to thermal stress can have enhanced temperature resistance. The CRC/TRR extends these approaches to include multifunctionality, so that HyPo-components achieve a significant performance increase compared to conventional approaches. For example, the integration of areas with variable magnetic properties opens possibilities for creating sensor systems within the components themselves. In summary, a comprehensive understanding of HyPo-structures expands component design by considering density variability, material properties, and multifunctionality, leading to a new level of application-optimised product design. The underlying scientific questions are highly interdisciplinary. To gain comprehensive knowledge regarding the manufacturing, design and characterisation of HyPo-components, close cooperation between the disciplines manufacturing technology, materials technology, metrology, mechanics, design and computer science is required. Only through this interdisciplinary cooperation can a fundamental understanding of the characteristics and correlations between manufacturing parameters and material properties be achieved. In the future, multifunctional hybrid and porous high-performance components are expected to make significant contributions to resource-saving and environmentally friendly products and manufacturing processes. They will enhance the energy efficiency and performance of a wide range of products, ensure product safety through component-integrated sensor technology, and facilitate data acquisition in the context of digitisation.

• DFG Programme: CRC/Transregios

Current projects

• A01 - Thermomechanical FE-FFT multiscale simulation of heterogeneous porous materials (Project Heads Scheunemann, Lisa ;  Staub, Sarah )
• A02 - Modelling of local failure mechanisms and macroscopic strength properties of HyPo-materials (Project Head Müller, Ralf )
• A03 - Multiscale-multiphase topology optimisation for components made of hybrid materials (Project Head Junker, Philipp )
• A04 - Integrated component monitoring of highly loaded hybrid porous components (Project Heads Bergmann, Benjamin ;  Klaas, Daniel )
• A05 - Modelling of Laser Directed Energy Deposition considering the resulting properties of hybrid porous structures (Project Heads Böß, Volker ;  de Payrebrune, Kristin )
• A06 - Component design with local density/material variability (Project Heads Koch, Oliver ;  Oehler, Manuel )
• A07 - Anomaly-driven reinforcement learning for process optimisation in additive manufacturing of hybrid materials (Project Heads Aurich, Jan C. ;  Fellenz, Sophie ;  Kloft, Marius )
• B01 - Laser directed energy deposition of functionally graded materials on porous metals (Project Head Aurich, Jan C. )
• B02 - Process-integrated foaming in additive manufacturing of hybrid components (Project Head Maier, Hans Jürgen )
• B03 - In situ characterisation of additively manufactured hybrid and porous components (Project Head Kästner, Markus )
• B04 - Graded hybrid and porous structures produced by additive fusion welding using customised filler materials and modified process technology (Project Head Hassel, Thomas )
• B05 - Model-based path planning and control (Project Heads Raatz, Annika ;  Seewig, Jörg )
• C01 - Influence of microstructural notches and stress gradients on the fatigue behaviour of additively manufactured HyPo-components (Project Head Beck, Tilmann )
• C02 - Mechanical properties of hybrid porous materials on the microscale (Project Head Kerscher, Eberhard )
• C03 - Characterisation of hybrid porous materials for process design (Project Heads Hinz, Lennart ;  Seewig, Jörg )
• C04 - Mechanical behaviour of hybrid components with gradients of the alloy composition (Project Heads Beck, Tilmann ;  Blinn, Bastian )
• C05 - Characterisation and optimisation of the tribological properties of hybrid porous components in lubricated conditions (Project Heads Koch, Oliver ;  Thielen, Stefan )
• INF - Information management and information infrastructure - Research data management for hybrid porous materials (Project Heads Koepler, Oliver ;  Nürnberger, Florian )
• MGK - Integrated Research Training Group (Project Head de Payrebrune, Kristin )
• S01 - Demonstrator for the potential of multifunctional high-performance components made of hybrid porous materials (central service project) (Project Heads Kirsch, Benjamin ;  Klemme, Heinrich )
• Z - Central Tasks (Project Head Aurich, Jan C. )

• Applicant Institution: Rheinland-Pfälzische Technische Universität Kaiserslautern-Landau
• Co-Applicant Institution: Gottfried Wilhelm Leibniz Universität Hannover
• Participating University: Technische Universität Darmstadt
• Participating Institution: Fraunhofer-Institut für Techno- und Wirtschaftsmathematik (ITWM); Technische Informationsbibliothek (TIB)
• Spokesperson: Professor Dr.-Ing. Jan C. Aurich