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

• 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