EPFL Rocket Team’s Post

The ship of the future should be lighter, consume less fuel and therefore emit less CO2. Shipyards are already experimenting with a mix of materials: the hull is still made of steel, while the superstructure is made of aluminum. To join the two difficult materials together, adapters are attached using explosion welding. A complex, dangerous, and expensive process. 💥 This is where our engineers from the Laser Application Center come into play: together with partners from industry and research institutes, they are working on a funded project to integrate this adapter using laser beam welding. They are pursuing a completely new approach: steel and aluminum are welded overlapping. The adapters to be joined are welded onto the aluminum sheet in an undercut with two intersecting laser beams. This ensures high strength and more freedom in design thanks to high formability. Our development team has designed a very special processing head with completely new requirements: it has to control not just one, but two simultaneously emitting beam sources. And that's not all: the welding depth also needs to be controlled. The outer large area of the laser steel (lower intensity) is used to melt a relatively higher proportion of steel in order to produce a more malleable structure. The inner part of the laser beam (higher intensity) is used to weld into the aluminum alloy. 💡 The tests will run until the end of the year. This gives the shipbuilding industry an opportunity to continue working competitively and sustainably at the same time. The FOLAMI funding project is financed by the Federal Ministry of Economics and Technology, supervised by Projektträger Jülich (PtJ). Laser Zentrum Hannover e.V. (LZH) Precitec - Laser Material Processing Coherent Laser Fraunhofer LBF Hilbig GmbH LASER On Demand GmbH FR. LURSSEN WERFT & CO MEYER WERFT GmbH & Co. KG #berlinindustrialgroup #scansonic #uniqueunited #laser #shipbuilding #lightweightconstruction #laserprocessing

𝐄𝐱𝐩𝐥𝐨𝐫𝐢𝐧𝐠 𝐭𝐡𝐞 𝐔𝐧𝐢𝐪𝐮𝐞 𝐏𝐫𝐨𝐩𝐞𝐫𝐭𝐢𝐞𝐬 𝐚𝐧𝐝 𝐀𝐩𝐩𝐥𝐢𝐜𝐚𝐭𝐢𝐨𝐧𝐬 𝐨𝐟 𝐌𝐞𝐭𝐚𝐥 𝐅𝐨𝐚𝐦𝐬 𝐢𝐧 𝐌𝐨𝐝𝐞𝐫𝐧 𝐈𝐧𝐝𝐮𝐬𝐭𝐫𝐢𝐞𝐬 Metal foams are lightweight, porous structures made from metals such as aluminum, titanium, or nickel, featuring a high volume of gas-filled spaces that give them a sponge-like appearance. These materials possess a unique combination of properties, including low density, high stiffness, and excellent energy absorption capacity, which makes them ideal for applications in industries like automotive, aerospace, and construction. The structure of metal foams allows for significant weight reduction without compromising structural integrity, which is highly beneficial in the transportation industry where reducing fuel consumption and emissions is a priority. Additionally, metal foams have good thermal conductivity and can function as heat exchangers or thermal management systems in electronics and other high-performance devices. 𝐃𝐢𝐬𝐜𝐨𝐯𝐞𝐫 𝐡𝐨𝐰 𝐦𝐞𝐭𝐚𝐥 𝐟𝐨𝐚𝐦𝐬 𝐜𝐚𝐧 𝐫𝐞𝐯𝐨𝐥𝐮𝐭𝐢𝐨𝐧𝐢𝐳𝐞 𝐲𝐨𝐮𝐫 𝐩𝐫𝐨𝐣𝐞𝐜𝐭𝐬 𝐰𝐢𝐭𝐡 𝐭𝐡𝐞𝐢𝐫 𝐥𝐢𝐠𝐡𝐭𝐰𝐞𝐢𝐠𝐡𝐭 𝐬𝐭𝐫𝐞𝐧𝐠𝐭𝐡 𝐚𝐧𝐝 𝐚𝐝𝐯𝐚𝐧𝐜𝐞𝐝 𝐞𝐧𝐞𝐫𝐠𝐲 𝐚𝐛𝐬𝐨𝐫𝐩𝐭𝐢𝐨𝐧 𝐜𝐚𝐩𝐚𝐛𝐢𝐥𝐢𝐭𝐢𝐞𝐬. 𝐋𝐞𝐚𝐫𝐧 𝐦𝐨𝐫𝐞 𝐭𝐨𝐝𝐚𝐲 @https://lnkd.in/dM79XPCX In terms of performance, metal foams also offer superior mechanical properties, particularly in absorbing impact energy, making them valuable in safety applications such as crash-resistant vehicle components or protective equipment. The high surface-area-to-volume ratio of metal foams can also improve their effectiveness in catalytic converters or filtration systems, as the porous structure enables better interaction with gases or liquids passing through. However, the production of metal foams can be expensive, and controlling the uniformity of the pores remains a challenge, limiting their wider adoption. Nevertheless, advances in manufacturing technologies, including additive manufacturing, are improving cost efficiency and structural control, paving the way for broader use of metal foams in diverse industries. 𝐌𝐚𝐣𝐨𝐫 𝐏𝐥𝐚𝐲𝐞𝐫𝐬 ERG Aerospace Cymat Technologies Ltd Mott MacDonald Ultramet, Inc. Alantum Havel metal foam GmbH Mayser GmbH & Co. KG Pohltech American Elements #MetalFoam #LightweightMaterials #EnergyAbsorption #InnovativeEngineering #AdvancedMaterials #AerospaceTech #AutomotiveInnovation #SustainableSolutions #MaterialScience #EngineeringInnovation

Did you know Summit has the ability to self-perform the major structural foundation work on your next project? #Construction #Semiconductor #Modules #Safety #Summit #SummitIndustrial #OSM #OffSiteManufacturing #Modules #Trestles #Piperacks #BatteryEV #SolarMFG #AdvancedTech #IndustrialManufacturing #ModularFabrication #Foundations

As the ARC Training Centre for Surface Engineering of Advanced Materials (SEAM_ARC) concludes its 5-year journey of industrial research collaborations, the impact of its work is becoming clear. The September issue of Materials Australia magazine highlights three standout projects. We are proud to have been an industrial partner in two of them. Read more here ➡ https://lnkd.in/gwAc3GWD Andre Hatem’s research focused on the mechanical properties, as well as wear and corrosion performance of the stainless steel AISI 431, applied as an additively manufactured structure using #lasercladding. His findings enable LaserBond to deliver claddings and AM structures with enhanced quality and performance to our customers. Alexander Osi led the design and testing of a lightweight hydraulic piston rod, featuring a HVOF WC-NiCr coating, reducing overall weight by an impressive 63%. This project was conducted in partnership with MacTaggart Scott and DMTC Ltd. Ryan Yeates from MacTaggart Scott notes that this project has created “not just a theory but a piece of hardware we can take to industry”. #AdditiveManufacturing #thermalspraying #lasermetaldeposition #HVOF #DED #surfaceengineering #industrialresearch #defence

Today, another insight into the development of complex composite products. Would you like to know how you can reduce the risk of product development in the early design phases? How to automatically generate digital product variants? How your manufacturing process decisions affect the overall production, assembly and balance of your production line? Would you like to know how to optimize your resources? Want to learn more? Visit Fraunhofer IGCV at the JEC in Hall 6, booth Q28.

𝐓𝐚𝐜𝐤𝐥𝐢𝐧𝐠 𝐂𝐡𝐚𝐥𝐥𝐞𝐧𝐠𝐞𝐬 𝐢𝐧 𝐌𝐮𝐥𝐭𝐢-𝐌𝐚𝐭𝐞𝐫𝐢𝐚𝐥 𝐉𝐨𝐢𝐧𝐢𝐧𝐠 𝐟𝐨𝐫 𝐁𝐨𝐝𝐲 𝐄𝐧𝐠𝐢𝐧𝐞𝐞𝐫𝐢𝐧𝐠 In the world of automotive design, multi-material construction is the new standard. But with innovation comes challenges – especially when it comes to joining materials like aluminum and steel, which traditionally don’t play well together due to thermal incompatibility. Böllhoff’s has a solution - WELTAC: a game-changing resistance element welding technology that brings unparalleled flexibility to the assembly line. Now, lightweight materials can be seamlessly joined with steel of all grades, unlocking new possibilities in car body construction. The best part? You don’t need to overhaul your existing setup. WELTAC is designed to work with 𝗰𝗼𝗻𝘃𝗲𝗻𝘁𝗶𝗼𝗻𝗮𝗹 𝘀𝗽𝗼𝘁 𝘄𝗲𝗹𝗱𝗶𝗻𝗴 𝗲𝗾𝘂𝗶𝗽𝗺𝗲𝗻𝘁, making it a smart, cost-effective solution for modern manufacturing needs. #AutomotiveDesign #ManufacturingInnovation #LightweightDesign 𝐶𝑟𝑒𝑑𝑖𝑡 : 𝐵𝑜̈𝑙𝑙ℎ𝑜𝑓

The steel industry has been witnessing significant advancements in material science, aiming to develop alloys that meet the demanding requirements of modern engineering applications. One such innovation is Balev Steel, developed by #Centravis. This advanced stainless steel offers enhanced mechanical properties, corrosion resistance, and reduced weight. But how do these improved properties affect its weldability and workability? This article delves into the technical aspects of Balev Steel, providing insights valuable to engineers, metallurgists, and energy specialists: https://lnkd.in/esYuVBkh #Sustainability #GreenTech #BalevSteel

#TeamSalix Engineering spotlight - Wheel Interface Study   A wheel interface study is completed during the design stage to identify all the safety critical areas which can impact the performance of our turnouts. For this project, Salix performs the wheel interface study based on worst tolerance stack-up analysis. Our team identify any possible issues during the design phase and make necessary improvements, ensuring the safety in design and product performance prior to manufacturing. In the simulation below, the wheel runs over the K-crossing, dual V-crossing entry and exit points. Our engineering team then asses any issues or gaps and update the design to suit before manufacturing. The results were presented to our clients in a detailed design report.   All parts below were designed and manufactured by Salix. #salixengineering #wheelinterfacestudy #rail #turnouts

🚄✨ Exploring the Alumino-Thermit Welding Reaction: Where Science Meets Innovation! ✨🛤️ At Amiable Impex, we're not just about providing solutions; we're passionate about delving into the science behind them. Today, let's embark on a journey into the fascinating realm of Alumino-Thermit Welding Reaction! 🔬 The Science Unraveled: Alumino-Thermit welding operates on a principle deeply rooted in chemistry and physics. The reaction involves the exothermic oxidation of aluminum powder in the presence of iron oxide. 🔥 Heat of the Moment: This reaction releases an incredible amount of heat – temperatures soaring to over 2500°C! Such intense heat is what makes Alumino-Thermit welding a preferred choice for joining railway tracks and other heavy-duty applications. 💡 Understanding the Alchemy : When aluminum powder reacts with iron oxide, it strips oxygen from the iron oxide, resulting in the formation of molten iron and aluminum oxide. The liberated molten iron then fills the joint between the rails, creating a seamless bond upon cooling. 🛠️ Engineering Marvel: What makes Alumino-Thermit welding truly remarkable is its precision and efficiency. By harnessing the power of this reaction, we can achieve welds of exceptional quality, ensuring the durability and reliability of railway tracks for years to come. 🌱 Green Chemistry: Beyond its technical prowess, Alumino-Thermit welding aligns with sustainable practices. With minimal environmental impact compared to traditional welding methods, it stands as a beacon of eco-friendly engineering. 🌐 Global Impact : From urban metros to sprawling transcontinental railways, Alumino-Thermit welding is shaping the future of transportation infrastructure worldwide. At Amiable Impex, we take pride in contributing to this global revolution. 👨🔬 Join Us on this Journey: As we continue to push the boundaries of innovation, we invite you to be a part of our quest for excellence. Together, let's explore the endless possibilities of Alumino-Thermit welding and pave the way for a brighter, more connected future. 🔗 Connect with Us: Ready to learn more about Alumino-Thermit welding and its transformative potential? Reach out to us today and let's spark a conversation that ignites innovation! #AmiableImpex #AluminoThermitWelding #Innovation #EngineeringMarvel #SustainableFuture #RailwayInfrastructure #ScienceAndTechnology

👀 Did you know that waterjet cutting is applied in industries as diverse as metalworking, aerospace, construction and automotive?   This versatile cutting method can cut a wide range of materials, from metals and plastics to glass, ceramics and stone. Its main advantages include: -      Clean cuts -      No thermal deformation -      Environmental friendliness -      Three-dimensional capability.   Discover the power of waterjet cutting with COMPOSITES MARTIARTU | SMC | CF-SMC and unleash your potential for innovation in multiple industries! #WaterjetCutting #Engineering #composites #moulding