TRR 375 HyPo - Multifunctional High-Performance Components made of hybrid porous materials

A new class of components is being researched in the Collaborative Research Center / Transregio 375: multifunctional high-performance components made of hybrid porous materials (HyPo). These materials combine various metallic materials with purposefully introduced pores in order to achieve locally varying mechanical and thermal properties. In addition to high strength and low weight, the components should also enable permanent self-monitoring thanks to integrated sensors, which means that their service life can be better utilized.

In TRR 375, the match is working on the central sub-project B05, which focuses on additive manufacturing using wire arc additive manufacturing (WAAM). Methods are being developed here to optimize manufacturing processes through adaptive, model-based path planning. This is necessary in order to realize the complex material properties of the HyPo components.

One of the biggest challenges is taking various process-determining factors into account. These include the time- and location-dependent temperature profile, the material feed, the application speed and the energy supplied. Comprehensive parameter studies and the development of new control concepts are being used to investigate how these factors can be specifically controlled in order to enable a stable and efficient manufacturing process.

WAAM offers promising possibilities here. This process uses an electric arc to apply wire material layer by layer and build up components step by step. The high energy efficiency and suitability for large-scale structures make WAAM an important component of research. The aim is to use adaptive process control not only to react to deviations in the manufacturing process, but also to actively influence the properties of the manufactured components. For example, the local porosity can be specifically adjusted in order to achieve an optimum combination of stability and weight.

The match is working closely with other TRR 375 research institutions to develop a practical and robust manufacturing process for HyPo materials by 2027. The knowledge gained should contribute to increasing efficiency in production technology in the long term and enable innovative applications in various industrial sectors.