Materials and component testing

Expertise and experience in the field of component and materials testing

Component testing is a process in which entire components or individual parts of a product are checked for functionality, purity, resilience, and quality based on defined standards and specifications. Fraunhofer IMWS supports manufacturers and customers in this process with excellent expertise and extensive equipment.

© Fraunhofer IMWS
4-point bending test with optical measurement.

Which test method is suitable for my component?

The method and scope of testing depends on the type of component and the requirements. The behavior under thermal, chemical, or mechanical stress is examined. Component testing can be performed manually or automatically. It is also possible to test individual materials. In materials testing, on the other hand, the behavior and material properties of material samples are determined. The testing of components and materials is of great importance in order to ensure quality, safety, and reliability and to guarantee compliance with industrial standards and regulations.

A fundamental distinction is made between destructive testing and non-destructive testing in both component testing and materials testing. The Fraunhofer IMWS has state-of-the-art equipment and many years of expertise available for both variants. As a methodologically oriented Fraunhofer institute in the disciplines of materials science and materials engineering, we are the point of contact for industry and public clients and address issues relating to the microstructure of materials and systems – with the aim of increasing material efficiency and cost-effectiveness and conserving resources. We offer research work and collaboration across the entire development chain, from material design to tested prototype components.

Benefits of component testing at Fraunhofer IMWS

 

  • Ensuring product quality: Component testing enables manufacturers to ensure that their products meet quality standards and satisfy customer expectations. This contributes to customer satisfaction and strengthens brand reputation.
  • Avoiding product defects: Early detection of defects or irregularities in components helps to avoid potential product defects that could lead to costly recalls or repairs.
  • Ensuring safety: Component testing helps to ensure that products are safe and reliable. This is particularly important in safety-critical industries such as aerospace and medical engineering.
  • Cost efficiency: By testing components, potential problems can be identified and rectified at an early stage, which can lead to cost savings in the long term. Early identification of defects reduces the risk for manufacturers, particularly in the development phase, and increases efficiency in terms of material usage and device design.
© Fraunhofer IMWS
SCB test (single cantilever beam) on sandwich panels to evaluate crack propagation and characterize the bond between the deck layer and the core.

We offer

  • Design and optimization of highly stressed fiber composite structures and components through numerical simulation
  • Determination of mechanical and physical material properties of fiber composite materials and sandwich core materials
  • Development and implementation of structure and component tests (e.g., sandwich shells)
  • Non-destructive material and component testing
  • Evaluation of the damage tolerance of fiber composite materials and structures using fracture mechanics methods (including for predicting the service life of damaged structures)
  • Mesostructure and mechanism-based simulation methods for analyzing structure-property correlations (e.g., RVE modeling)
  • Analysis of service life and aging behavior (e.g., under environmental influences)

Component testing on the multiaxial test rig

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      Preparation and testing of components and materials at Fraunhofer IMWS

       

      Component testing of substructures for photovoltaic modules

       

      Component testing of fiber composite materials

       

      Holistic evaluation of sandwich structures for lightweight construction applications

       

      Conditioning of test specimens for component testing

      Portfolio Material and component testing at Fraunhofer IMWS

      Mechanical testing

      Simulation

      Non-destructive testing

      Rheological test methods

      Thermal testing

      Optical testing methods

      Project selection

       

      Lightweight, efficient, and suitable for series production due to sandwich construction with thermoplastic materials

      The flap, made from thermoplastic sandwich semi-finished products, demonstrates the enormous potential for weight reduction offered by thermoplastic sandwich molding technology.

       

      Innovative structural components with adapted electronics for electric vehicles

      Together with partners, Fraunhofer IMWS is conducting research into the manufacture of innovative lightweight vehicle structures with integrated electronic components for electric cars as part of the interdisciplinary project “InThElekt.”

       

      Investigation of the lightweight construction potential of hierarchically structured sandwich materials

      The aim of the "HPHex" project was to investigate the lightweight construction potential of new hierarchically structured sandwich materials that can be manufactured cost-effectively in highly automated production processes.

       

      High-performance lightweight materials for aircraft construction

      High-quality, sophisticated composite materials for lightweight construction already play a key role in the aircraft industry. Fraunhofer IMWS and aviation supplier P-D Aircraft Interior want to make these materials even more robust by using glass fibers.

       

      Digital twin for thermoplastic composites “digitalTPC”

      In the “digitalTPC” project, employees from Fraunhofer IMWS, Fraunhofer ICT, Fraunhofer IZFP, and Fraunhofer SCAI are working with industry representatives to develop a digital twin for thermoplastic composites, taking a holistic view of the real and virtual process chain.

       

      Efficient lightweight sandwich structures with high surface quality

      Fraunhofer IMWS is working with partners to develop highly resilient structural components with smooth, visually appealing surfaces and the appropriate processes for manufacturing and quality testing. The partners are focusing on metal-plastic hybrid sandwich materials.

       

      Damage-tolerant CFRP foam sandwich structures for aircraft construction

      The SANDWICH² project, part of the LuFo V aerospace research program, focuses on investigating and optimizing the damage tolerance of such foam sandwich structures. The Fraunhofer IMWS is part of the research consortium and responsible for this research.

       

      Hierarchical thermoplastic sandwich materials for even more efficient lightweight construction

      The Fraunhofer IMWS and ThermHex Waben GmbH are working together on a new type of technology. They are focusing on hierarchical sandwich structures in which the cover layers themselves are sandwich structures in order to make lightweight construction even more efficient.

       

      Lightweight construction for aviation: Fraunhofer IMWS tests the safe use of new materials

      Lightweight construction is crucial in aviation in order to save fuel and thus reduce emissions. Can carbon fiber-reinforced sandwich components be used for the load-bearing structures of an aircraft?