Component Design

Fraunhofer Center HTL offers component design and material selection as a consulting service. Commercially available finite element (FE) programs (ANSYS, COMSOL) are available for stress and deformation analysis, as well as interfaces to CAD and CAE tools. The HTL develops low-stress designs through the simulation of mechanical and thermal load cases, utilizing automated methods for topology optimization. Material selection can be done according to customer requirements or systematically in line with the component design at the HTL. Component designs can be created to meet circular economy requirements, facilitating component exchange and reuse of less-stressed parts: design to disassembly. Once suitable materials are selected, components can be converted into production- and material-conforming designs. This includes both traditional manufacturing methods and additive manufacturing. Material-specific properties, such as ceramic-conforming design, are also considered. If necessary, corresponding prototypes and small series are produced and tested at the HTL.

Finite Element Analyses for Component Design

The simulation of component behavior includes loads from static temperature gradients or thermal shock/thermal cycling, as well as all types of mechanical loads and combinations of thermal and mechanical load cases. Within the framework of FE analyses, material fatigue can also be considered and service life predictions can be made. If not already known, necessary material data are determined through mechanical and thermal characterization methods. Anisotropic material properties can also be considered in component design. Weak points of the component are recognized based on FE analyses, and an optimal geometry for the specific component application is identified.

Component Design for Hybrid Components

Ceramic and metallic components can be combined using different joining methods to utilize the specific advantages of both material classes (publication: Joining of Ceramic and Metal Parts). Component design takes into account the different expansion behavior and the special requirements of load-conforming joining technology. Existing components can be precisely measured using computed tomography, and this data can be used for calculation and redesign of component design.

Our Services:

  • Creation of studies for component design and material selection
  • FE modelling of the operational behavior under thermal and mechanical loads
  • Component design
  • Design to Disassembly
  • Ceramic-conforming component design
  • Structural design of CMC components
  • Design of components for 3D printing
  • Construction of manufacturing aids for component production
  • Creation of service life predictions

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Topology Optimization

Modern methods of topology optimization make it possible to develop application-specific ceramic and metallic components with minimal mass and heat capacity.

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