Steinbeis Innovation Center Intelligent Functional Materials, Welding and Joining Techniques, Implementation

Applied research, development, engineering design, and technology exploitation
 

• Materials science:
  • Lightweight functional materials
  • Shape-memory alloys (smart materials)
  • Particle-reinforced/fibre-reinforced composites
  • Welding of different materials, multi-material mixes, and application-optimized materials
  • Enhancement of material properties
  • surface treatment
• Joining technology/welding:
  • Electric arc and beam welding processes
  • Mechanical joining techniques
  • Hybrid joining techniques
  • Resistance welding and HFI welding processes
  • Manual, robotic, plasma, submerged arc, TIG, and  MIG/MAG welding
  • Welding equipment and devices
• Components/exploitaton:
  • End-to-end design of joined components and component assemblies
  • Numerical simulation of functional materials and joint connections
  • Market analysis on the state of art of joining technology and applications
  • Pre-sales and marketing

• Lightweight design
  • Metal lightweight construction materials (aluminum, magnesium, high-strength steels, basalt fiber composites, particle-reinforced composites, e.g. thermosetting plastic, thermosetting)
  • Smart lightweight functional materials; nano-doping of polymers with integrated electric/thermal conductivity
  • Graphite nano-particle doping for lightweight construction materials
  • Complex component design with functional materials and integrated joining technology; design of different types of joins and geometries
• Digital solutions and artificial intelligence
  • Development of innovative physical functional principles for newly designed functional components, joining torches, and joining tools
  • Smart monitoring and fault detection systems using sensors, analysis, and evaluation
  • Additive manufacturing (AM technology) of component structures with defined features using 3D weld cladding involving plasma and laser welding techniques
  • Mechanization, process automation, inline monitoring of joining processes, and online testing of joining techniques
• Joining and welding technoloy
  • Mixed construction, mixed joints, and multimaterial mixing of application-optimized materials
  • Numerical simulation (metaphysical, process, and  structural simulation) on thermodynamic processes involving thermal/mechanical joints, also involving simulation of the strength and residual stress of joined components
  • Functionalization of materials and component surfaces using plasma and laser beam processes
  • TIG, MSG, and MIG/MAG arc welding, plasma arc welding, and cutting processes – hybrid welding processes
  • Electric arc processes: laser and electron beam welding
  • Laminating, weld cladding, hardening, and soldering of metallic and non-metallic materials
  • Resistance welding, HFI welding, friction welding, and friction stir welding
  • Mechanical joining techniques (clinching, flow-drilling, bracketing, etc.) and different hybrid welding techniques
  • Market analysis on manufacturing processes used for materials, joining technology, joining technology production planning, configuration/workflow organization
• Joining technology – the environment and health
  • Planning and development of metallic and non-metallic filler materials for screening electromagnetic radiation and improving the use of such materials in electric cars and electronics
  • Development of non-hazardous and environmentally friendly processing and machine technologies for manufacturing specific products or materials
  • Development of energy-efficient high-performance equipment and modules for different industrial applications
  • Development of special joining technology for manufacturing pharmaceutical devices and application-specific tools

• Development of new types of thermogas-kinetic high performance forming processes for producing magnesium components with advanced reshaping properties for the automotive industry
• Surface treatment of basalt fiber thermosetting plastic tapes with integrated functional elements using plasma treatment
• Development of TIG cold wire welding processes with non-transferred electric arcs involving thermal joining of steel/polymer/steel-composites
• Development of a new TIG robotic welding device using an adaptive replaceable nozzle system and heatpipe thermal heat dissipation
• Development of a monitoring system for detecting weld defects and regulating TIG welding processes using acoustic emission analysis
• Development of innovative welding technology for intermetallic component joining involving conditioning of the welding process using cold and/or hot gas from a vortex tube
• Development of a process for manufacturing powdery, nano-scale solid materials and dispersions
• Development of a system for producing thin tribological hard layers using laser hybrid technology for prismatic component surfaces
• Development of a new type of orbital micro-plasma powder welding torch with a compact guidance system for coating inside pipes and similar components
• Tribologically optimized inner surfaces of cylinders using macro and nano hard coatings for Tribop extruder bushes
• Development of a process for the precise, selective application of repair coatings using extremely fine powders
• Development of welding powders and corresponding technology for submerged arc welding of thick-walled aluminum parts
• Development of non-hazardous and environmentally friendly processing and machine technologies for manufacturing flux for AI submerged arc welding
• Development/characterization of an elastomer surface coating system on metal surfaces with the right properties for electromagnetically shielding and protecting against corrosion using butyl rubber 

Steinbeis Transfer Magazine

• A process with dual benefits: quality in manufacturing, efficiency in recycling (Transfer 1/2026)
  Steinbeis experts develop an automated, open plasma arc melting process
  
  In this project, the Steinbeis Innovation Center for Intelligent Functional Materials, Welding and Joining Technologies, Exploitation, together with SMP Schüßler Modell- und Prototypenbau, developed an automated plasma arc melting system for aluminum casting and metal recycling. Author Khaled Alaluss demonstrates that the technology enables high-quality cast components, energy-efficient recovery of metal resources, and sustainable, flexible manufacturing processes.
• It’s All About the Combination – Welding and Forming in One (Transfer 1/2024)
  Steinbeis experts develop process technology for the automated arc welding and forming of high-strength steel structural components
• A Clever Way to Monitor Welding Processes (Transfer 1/2023)
  Steinbeis experts and project partners develop a multi-module sensor system
• Careful! It’s Hot and Cuts Like a Knife (Transfer 3/2022)
  Steinbeis experts develop a plasma cutting torch for the thermal cutting of multi-material components
• Success in Rotation (Transfer 3/2021)
  Steinbeis experts develop a plasma welding burner using a mechanical rotating light arc for bonding and weld overlaying
• That Seals It (Transfer 1/2021)
  Steinbeis experts develop process technology for thermal joining of multimaterial components and composite structural components
• The Protection Professionals (Transfer 2/2020)
  Working in collaboration with Isocoll Chemicals, Steinbeis develops an elastomer surface coating system based on filled butyl rubber.
• Welded Safe and Sound (Transfer 1/2020)
  Steinbeis experts develop non-hazardous and environmentally friendly processing and machine technology for producing welding powders
• To the Point (Transfer 2/2019)
  To the Point Steinbeis experts develop a process for selectively adding coatings using extremely fine powder particles
• Finding Defects Acoustically (Transfer 1/2019)
  A Steinbeis test measurement system can detect welding defects using acoustic emission analysis
• Well Welded, Whatever the Position (Transfer 2/2018)
  Steinbeis experts develop orbital micro-plasma powder welding torch
• Good vibrations (Transfer 4/2017)
  Steinbeis experts develop laser coating technique by using vibrations
• Full Steam Ahead for Basalt Fiber Production (Transfer 2/2017)
  Steinbeis experts develop process for purifying and activating basalt fibers
• Using Coatings to add Pressure (Transfer 4/2016)
  Steinbeis works with manufacturing partner to develop rough surfaces on extrusion bushes
• Creating a Strong Bond (Transfer 3/2016)
  A team of Steinbeis experts develops a process for thermally joining coated composites
• Innovative Welding of Solid Components (Transfer 2/2016)
  Steinbeis project team develops welding process and welding powder