FRAUNHOFER INSTITUTE FOR HIGH-SPEED DYNAMICS, ERNST-MACH-INSTITUT, EMI PROFILE OF THE INSTITUTE

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1 FRAUNHOFER INSTITUTE FOR HIGH-SPEED DYNAMICS, ERNST-MACH-INSTITUT, EMI PROFILE OF THE INSTITUTE

2 Profile of the institute Who we are Our service offer Fraunhofer Institute for High-Speed Dynamics, Ernst-Mach- Institut, EMI, is an institute of the Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e. V. A distinctive feature of the institutes and research units of the Fraunhofer-Gesellschaft is their scientific excellence arising from their integration into the academic research landscape while networking well with the industries. At this interface, we conduct basic preliminary research but also system development in an economic manner. Ernst-Mach-Institut has specialized in investigating physicaltechnical processes in materials, structures and components as they occur, for instance, during crash or impact. Our research contributes to increased safety and security, reliability, resilience and sustainability in our society. Our mission In our business units Defense, Security, Automotive, Space and Aviation, we aspire to offer first-class research services and cutting-edge technology to our customers from the industries and the public sector. For this achievement, we focus on solutions for safety and security, reliability and resilience. We distinguish ourselves by in-house development of testing facilities, measuring instruments, sensors and software as well as by our own workshops, a high percentage of technical staff and a good mixture of senior scientists and PhD students. Thereby, we are able to flexibly adjust to individual requirements. What we provide for you Analysis and modeling of materials and components under dynamic loads Implementation and development of new sensors and measurement techniques Use and development of numerical calculation methods as well as customized software solutions Experimental examination of high-speed impacts of up to 10,000 meters per second Optimization of lightweight structures Analysis and solutions for the security of buildings and plants For the German Federal Ministry of Defence (BMVg), we act as excellent and independent partner with our analysis and consulting expertise concerning questions of research and technology. We derive our scientific strength and unique characteristics from being a one-stop source offering the combination of highspeed dynamics in experiment, modeling and simulation as well as engineering methods and technology. Our network Not only are we linked up with other Fraunhofer Institutes by means of alliances and groups, but we also entertain relations with universities and research facilities and industrial enterprises in Germany, Europe, America, Asia and Australia. The University of Freiburg and the five Fraunhofer Institutes located in Freiburg have founded the Sustainability Center Freiburg. In combination with the industry, this cooperation promotes the transfer of scientific developments into marketable and practice-oriented products and services. Our equipment At our disposal among others Laboratory acceleration facilities unique to Europe The Crash Center of the Fraunhofer-Gesellschaft covering component crash as well as full-vehicle crash for research purposes Testing laboratories with split Hopkinson pressure bar, universal and servo-hydraulic testing machines, drop-weight towers, multiaxial test bench Shock-tube facility for the examination of building elements (windows, doors, walls etc.) under blast loads Photo: Fraunhofer EMI in Freiburg. Open-area test site for explosions and indoor detonation chamber Laser sintering plant for additive manufacturing (3D printing) Excellent technology for measurement, diagnostics and visualization of high-speed processes Commercial and in-house simulation software Nondestructive test procedures Climatic chamber 1 2

3 Business unit Defense Business unit Defense Conception and analysis of protective mechanisms Numerical simulation of impact and shock-wave events Material characterization and failure analysis Development of sensor technology and electronic engineering for extreme conditions, high-speed measurement technology Analyses concerning technical safety and reliability of defense-related systems The business unit Defense focusses on the areas of protection and effectiveness. Modern protection concepts and new materials are analyzed with regard to high-dynamic loading, sensor systems are developed for their application in ballistics as well as practice-oriented engineering software. Furthermore, analyses concerning the technical safety and reliability of defense-related technology systems are included in our portfolio. By means of our acceleration facilities, we are able to accelerate masses ranging from only few milligrams to several hundreds of kilograms to a velocity of up to 10,000 meters per second in order to analyze terminal ballistic mechanisms. Another field of activity concerns laser effects. For the investigation of detonations under laboratory conditions, we resort to measurement technology partly unique to the world. The use of imaging techniques such as flash X-ray and specific high-speed cameras form a standard in this context. The theoretical analysis of impact and shock-wave events is based on numerical simulations calculated by means of material models created at EMI. The characteristic values for these models are measured under high-dynamic loading conditions at the institute itself. The mechanical inspection of materials regarding the vulnerability of aerostructures is conducted under realistic conditions. For automotive protection, the effects of shoulder weapons, mines and improvised explosive devices (IEDs) are analyzed, and new approaches for defense against threats are developed. We optimize transparent armor systems for viewing panels as well as personal protective equipment. Methods known from the field of protective structures are used for the protection of camps. We also evaluate combinations of materials and composite materials with regard to their ballistic protective performance. Photo: Experimental setup in ballistics: laser effects on projectiles. Dr. Manfred Salk manfred.salk@emi.fraunhofer.de 3 4

4 Business unit Security Business unit Security In the business unit Security, Fraunhofer EMI develops By means of computer-assisted risk and resilience analyses, technologies, methods and concepts to make our society we simulate and predict the behavior of systems in exand its infrastructure robust, error-tolerant and resilient treme events. Urban planners and persons responsible for towards hazards like terrorist attacks, natural catastrophes cities and communities are able to conduct profound risk or accidents. management (also in compliance with ISO 31000) with the aid of in-house developed interactive web applications One area of focus is the protection of buildings and supporting the process of decision-making. infrastructure against extreme loads such as explosions, fire, strong-wind incidents as well as earthquake or flood. The technical reliability and robustness of safety-critical Specially developed software applications allow for the systems in infrastructure and safety of control software calculation of limiting values for the dynamic load-carrying are also analyzed at EMI. These investigations incorporate capacity of conventional materials as reinforced concrete, mechanical, electronic, pyrotechnical and software-technical components of the system. Employing modeling and masonry, glass and their strengthening options. Apart from direct structural measures, Fraunhofer EMI researches analysis of extreme events, we give advice to system novel sensor technologies which support relief forces in res- developers who strive for their respective systems to be cuing endangered and injured people as fast as possible. designed to minimize risk and optimize security. Protection of buildings and infrastructure against explosions Risk analyses of extraordinary loadings Risk management for urban security Sensor technologies for safety and security applications Safety, efficiency and robustness analyses of technical systems Testing and certification Photo: In our shock-tube facility BlastStar, glass panels are tested for safety in case of explosion. Dr. Tobias Leismann Dr. Alexander Stolz 5 6

5 Business unit Automotive Business unit Automotive The crashworthiness of vehicle structures and components as well as the challenges concerning electromobility and automated driving are addressed in the business unit Automotive. The mechanical characterization and numerical modeling of materials, composites and components under static, dynamic and impact loading are main areas of research at Fraunhofer EMI. Alongside standardized test methods, we increasingly employ methods for micro- and nanostructure analysis in order to closely analyze vehicles under crash loading. As a consequence, we can investigate material characteristics even in the range of very small length scales. Actually, the behavior of the inner vehicle structures under crash can be rendered visible by means of X-rays. In our own component and research crash-test facility, we test the structural design of modern vehicles. Furthermore, we examine the crashworthiness of uncharged and charged batteries for electric vehicles at our own test bench. Numerical modeling forms an important core theme. Here, findings on materials and component structures gained from experiment are numerically tested and validated, and predictions about loads occurring in the case of crash can be made. Apart from commercial simulation software, we also use SOPHIA, a software developed in-house at EMI. EMI addresses the challenges of automated driving by analyzing the technical reliability and safety of electronic systems operated in the vehicle. Hardware and software systems are tested, diagnostic tools for high-voltage components are developed, and the technical system of the vehicle is modeled. The Crash Center of the Fraunhofer-Gesellschaft Characterization as well as numerical simulation and modeling of materials Examination of crashworthiness as well as optimization of lightweight structures Safety of batteries and energy storage for electromobility Technical safety of vehicles Photo: Our research crash-test facility at Fraunhofer EMI in Efringen-Kirchen. Dr. Jens Fritsch jens.fritsch@emi.fraunhofer.de 7 8

6 Business unit Space Business unit Space The safety of manned and unmanned space missions lies impact by particular aircraft can deflect the trajectory of at the heart of research and development in the fields of asteroids in order to protect planet Earth. the business unit Space. Collisions even with microparticles be it meteoroids or space debris can damage EMI is also involved in the fields of satellite technology, spacecraft or satellites considerably. By means of our especially with regard to nanosatellites, and develops light-gas acceleration facilities unique across Europe, we hardware and software for CubeSat systems. Furthermore, a satellite ground station is supposed to support examine such hypervelocity impacts experimentally. Based on these experiments, we conduct risk analyses to calculate impact probabilities and effects on spacecraft. Our optimize and deploy them for telecommunications and the operation of own CubeSats, for example, in order to in-house developed vulnerability analysis software PIRAT earth observation. serves as a tool to calculate the risks for a specific mission in order to design the appropriate protection concepts. Space research at EMI makes an important contribution to space safety. Due to its unique facilities, the institute is an In addition to this, studies at EMI focus on the protection integral partner for national and international aerospace against asteroids and how the deliberately provoked industries as well as space agencies such as ESA. Photo: CubeSat from the nanosatellite family receiving hardware and software developed at EMI. Protection of space systems Impact analysis of near-earth objects Protection against impact of near-earth objects Technologies (hardware and software) for nanosatellites Prof. Dr. Frank Schäfer frank.schaefer@emi.fraunhofer.de 9 10

7 Business unit Aviation Business unit Aviation Characterization of materials Testing of structures, components and joints Modeling and optimization of lightweight structures Analysis and optimization of aircraft structures under impact of hail, debris or bird strike Acceleration tests for airplane seats, cabin structures etc. Analysis of lightning strike and development of lightning strike protection Materials used in aviation have to be both as light as possible and at the same time especially loadable and reliable. The business unit Aviation contributes to this goal by material characterization, testing of structures, components and joints as well as modeling and optimization of lightweight structures. For the testing of fiber-reinforced composites, metals and also hybrid materials and glass, we use standardized nondestructive and destructive testing methods, but we also increasingly apply methods for micro- and nanostructure analysis. This allows for the exploration of material properties even for the smallest length scales. Apart from well-equipped testing laboratories and a wide range of numerical methods, EMI also features the Crash Center of the Fraunhofer-Gesellschaft: Here, acceleration tests as they are mandatory, for example, for airplane seats, can be conducted. Furthermore, metallic components can be additively manufactured and optimized at EMI. Airplane structures are highly susceptible to impact due to bird strike, severe hail storms or debris lying on the runways. Combining experiment and simulation, we analyze the respective physical processes and profit from our many years of experience in the fields of material characterization, implementation and development of numerical methods and research of high-speed dynamical impact events in order to make structures more resistant. Lightning strikes pose another challenge in the fields of aviation. Using experimental and numerical analyses, we investigate the behavior of CFRP structures struck by lightning and design the suitable lightning protection. Photo: Mechanical material characterization: CFRP sample after dynamic tensile test. Dr. Michael May michael.may@emi.fraunhofer.de 11 12

8 us! How to work with us Research and development assignment In the classical case of cooperation, you place your order with us for material testing, process optimization, safety and security analyses etc. in order to meet research and development demands of your enterprise. We create customer-oriented solutions adjusting to your particular needs and requirements. Strategic partnerships This manner of long-term cooperation serves the basic preliminary research for a common goal as, for example, the development of new software, new testing methods, completely novel technologies or the employment of new materials. In cooperation with you, we explore the general feasibility of a concept, scopes of application and individual requirements. PhD program PhD students carry out research at EMI on behalf of a company setting the topic. This very practically oriented way of graduating not only serves the productive exchange between research and application but also prepares junior scientists for their career in the industries. Joint publicly funded projects Together with you and other partners where required, we apply for resources from public research funding for a shared project concept, be it at the national or European level. These projects are mostly designed for a three-year period and enable us to develop solutions to problems in close collaboration. Sustainability Center Freiburg The cooperation between the University of Freiburg, the five Fraunhofer Institutes located in Freiburg and industry promotes the transfer of scientific developments to marketable and practice-oriented products and services. Our institute management Director: Prof. Dr.-Ing. habil. Stefan Hiermaier Phone stefan.hiermaier@emi.fraunhofer.de Deputy directors: Dr. Tobias Leismann Phone tobias.leismann@emi.fraunhofer.de Prof. Dr. Frank Schäfer Phone frank.schaefer@emi.fraunhofer.de 13 14

9 Our locations Freiburg Efringen-Kirchen Kandern Eckerstrasse Freiburg, Germany Phone Press and Public Relations: Birgit Bindnagel info@emi.fraunhofer.de Am Klingelberg Efringen-Kirchen, Germany Am Christianswuhr Kandern, Germany Fraunhofer EMI, Freiburg 2016