RESEARCH NEWS
The Fraunhofer IWU in Germany now offers a solution for architects and builders who seek appealing and cost-effective options for striking facade elements with reliefs that reportedly have “ nearly limitless shape and colour possibilities and do not require expensive forming tools .”
Whether for private , public or commercial properties , incrementally formed facade elements are worth considering . The process is suitable for creating larger and smaller metallic elements in the outer shell . At the new forming portal in the Chemnitz Research Institute , currently the largest facility of its kind in Germany , steel and aluminium sheets with dimensions of up to 4 x 2m and a ‘ bulging ’ depth of up to 75cm can be shaped “ into almost any form .”
Fraunhofer IWU teamed up with facade builder , Wirth & Co . GmbH , and coatings specialist , WOBEK-Design GmbH , to develop example elements in a joint project to demonstrate the technological possibilities . They decided to use the shape of a fish in several colour variations .
“ The coloured coating emphasizes the three-dimensional effect of the form and provides reliable weather protection . The side of the metal sheet opposite the forming tool ( punch ) first receives a form-stable , white powder coating . The subsequent application of a coloured inkjet print is also elastic and undamaged by the sheet metal forming . The coating process is complete when a UV-resistant clear coat , the only layer applied after the forming process , has been applied . It seals any areas of the painted surface that may have become porous due to the metalworking ,” explained Fraunhofer IWU to ISMR .
3D metal facades in colour
processes . Using the example of the The three-dimensional effect of the relief depends upon approximately 2m-long , 1m-high and nearly several factors , including the distance of the viewer . 20cm-deep fish , the project team calculated that up to a production volume of 185 , incremental forming is more economical than the significantly faster deep drawing ,” added Fraunhofer IWU .
The researchers are also considering fastening requirements to avoid unnecessary limits on design possibilities and meet the trend for closed , energy-efficient facades .
A further IWU team has proposed bonding The three-dimensional effect of the relief also depends elements made from inexpensive plastic upon the viewing angle . granules , allowing facade elements to be attached to curved surfaces .
The new portal facility also enables and simplifies the production of parts for which no forming tools are available . This is often the case with historic vehicles , as manufacturers are typically not required to keep expensive pressing tools available
Incremental sheet metal forming beyond ten years after production ends .
Artistic creativity can also be cost-effectively In the forming portal , a 12mm-diameter ‘ shaped ’ with incremental methods , said the punch gradually presses the required Fraunhofer IWU . shape into the sheet metal , based upon The German Federal Ministry for a corresponding 3D model . Complex
Economic Affairs and Climate Action geometries require a counter-form on the funded the project partners ( Fraunhofer back side of the sheet . The counter-form ’ s Institutes IWU and IFAM , along with material can be inexpensive plywood . Chiron SE ) through the IGF ( Industrial Joint Instead of a counter-form , manufacturers Research ) programme . The VDW Research may also use another forming tool or a Institute offered technical and organisational reusable pin cushion . support . n
“ The gradual forming process takes slightly more time but eliminates the need www . iwu . fraunhofer . de for the costly tools required in deep drawing
UK breakthrough in fusion-ready steel production
The Materials Processing Institute ( MPI ) has played a key role in the UK ’ s first large-scale production of fusion-ready steel .
“ This groundbreaking development promises to significantly lower manufacturing costs for advanced structural materials , while enhancing the efficiency of future nuclear fusion power plants . The breakthrough was delivered through the NEURONE ( Neutron Irradiation of Advanced Steels ) Consortium , a £ 12-million collaboration led by the UK Atomic Energy Authority ’ s ( UKAEA ) Materials Division , MPI and a network of academic and industrial partners ,” outlined MPI .
Using its seven-tonne Electric Arc Furnace ( EAF ) at its Middlesbrough campus in the UK , MPI successfully produced 5.5 tonnes of fusion-grade , reduced-activation , ferriticmartensitic ( RAFM ) steel . These highperformance steels are essential for nextgeneration nuclear fusion reactors , engineered to withstand extreme conditions including temperatures of up to 650 ° C and intense neutron radiation .
“ The project focused on adapting EAF technology , integrating advanced purification and heat treatment processes . This innovative approach has the potential to reduce the cost of RAFM steel production by up to ten times ,” added MPI .
NEURONE has also produced more than 50 different variants of advanced , reducedactivation , ferritic-martensitic ( ARAFM ) steel alloys for analysis . An evolution of RAFM steel , this presents opportunities for specialist UK steel manufacturers to contribute to future activity including forging , rolling and optimising manufacturing processes .
The Consortium , established to research , test and develop advanced steels , also includes representatives from the universities of Swansea ; Sheffield ; Birmingham ; Imperial College ; Manchester ; Bristol ; Strathclyde and Oxford , as well as Sheffield Forgemasters , in the UK and the Australian Nuclear Science and Technology Organisation . n
www . mpiuk . com
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