CarE-Service Training on Metal Reforming by Fraunhofer

This project has received funding from the European Union’s Horizon 2020 research and
innovation programme under grant agreement No 776851
Circular Economy oriented services for re-use and remanufacturing
of hybrid and electric vehicles components through smart and movable modules
Date

Please mute your microphone and open it only to ask questions in
the dedicated discussion slots at the end of each presentaion and in
the closing session
Use the chat to ask questions and submit comments during the
entire workshop
Raise your virtual hand if you want to ask a question in the
dedicated discussion slots
Presentations will be available for dowload in the CarE-Service
project website (www.careserviceproject.eu)
Connection recommendations

CarE-Service Dissemination Events
July 2021
October 2021
13th May (Training)
“Polyamides today:
from polymerization to recycling”
25th May (Training)
“Reforming technologies for re-manufacturing
of sheet metal parts, metals disassembly and
testing in automotive”
May 2021
June 2021
4th June (Demonstration)
"Innovative community platform for the reuse,
remanufacturing and recycling of metals,
techno-polymers and batteries in automotive”
“Automotive Polyamide Circularity?
Yes, it’s feasible”
5th July (Training)
"Mobile Solutions and Flexible lines for vehicles
battery dismantling”
21st July (Demonstration)
“New solutions for disassembly, remanufacturing
and testing automotive metal parts”
September 2021
20th September (Training)
“Battery Circular Economy approaches for
redesign, reuse and regulation”:
 Battery re-design: a sustainable
solution for the transition to Circular
Economy
 Second life battery applications:
challenges, solutions and case studies
 New Battery Regulation: implications
for the European battery value-chain”
18th October (Demonstration)
“Circular Economy holistic approach for
used batteries of electric and hybrid-electric
vehicles”
19th October (Demonstration)
“Circular economy-based mobility services”
October 2021
November 2021
25th November
(Final Exploitation Event)
The CarE-Service project will celebrate the
final event with a holistic discussion of
demonstrated results:
“Circular economy in the future automotive
market: new products and services generated
by the CarE- Service project"
(hosted by Fiat Chrysler Automobiles)

Agenda
11:00 Introduction
11:05 Introduction Video of Fraunhofer IWU
11:10 Reforming of sheet metal parts
11:25 De-Soldering of structural parts
11:40 Data management solutions
11:45 SMM - Smart mobile modules - Testing
12:05 Conclusion

This project has received funding from the European Union’s Horizon 2020
research and innovation programme under grant agreement No 776851
Project introduction
Dr. Thomas Hipke
Fraunhofer-Institute
for Machine Tools and Forming Technologies

Project figures
No Name Country
1 CONSIGLIO NAZIONALE DELLE RICERCHE* - Coordinator Italy
2 LINKOPINGS UNIVERSITET Sweden
3 ENVIROBAT ESPANA SL Spain
4 PRODIGENTIA - TECNOLOGIAS DE INFORMACAO SA Portugal
5 AGENCIA ESTATAL CONSEJO SUPERIOR DEINVESTIGACIONES CIENTIFICAS Spain
6 CIRCULAR ECONOMY SOLUTIONS GMBH Germany
7 COBAT SERVIZI Italy
8 FIAT CHRYSLER AUTOMOBILES ITALY SPA Italy
9 RADICI NOVACIPS SPA Italy
10 IMA MATERIALFORSCHUNG UND ANWENDUNGSTECHNIK GMBH Germany
11 FRAUNHOFER GESELLSCHAFT ZUR FOERDERUNG DER ANGEWANDTEN FORSCHUNG E.V Germany
12 AVICENNE DEVELOPPEMENT France
13 CIA AUTOMATION AND ROBOTICS SRL Italy
14 E-VAI SRL Italy
15 JRC -JOINT RESEARCH CENTREEUROPEAN COMMISSION Belgium

• Redesign E&HEVs for circular economy
• Develop EU leadership in advanced
technologies for re-use of E&HEVs
• Reduce TCO of E&HEVs
• Create new value chains and businesses in
EU around Circular Economy of E&HEVs
The concept of CarE-Service
Innovative
mobility
services for
citizens
based on
E&HEVs
• Increase citizens’ quality of life through
circular economy of E&HEVs
• Increase market acceptance and change
consumers’ behavior
• Guarantee return-flow of E&HEVs
• Increase market of innovative services
• New mobility services with upgrade
remanufactured parts
• Create a suitable regulatory framework

Mobile units bringing advanced technology for on-site disassembly and
testing/certification where is the demand
Disassembly Module
CarE-Service ICT Platform and Smart Mobile Modules (SMMs)
ICT Platform connecting demand and supply of re-usable parts and allowing the
coordination and optimization of the re-use value chain
Cloud-based CarE-
Service Platform
Testing Module
Manufacturer
End-user
Dismantlers
Recyclers Logistic
providers
Final certified
components
ready for
delivery

Demonstration
• Technical solutions in 3 re-use
value chains
• Re-use applications
• Mobility services
(multiple locations, customers
involvement)
• Overall business sustainability
• Social impact
Expected results
Exploitation
• Open industrial training
workshops
• Exploitation meetings
• First market replicators
• Regional Authorities involved
• White paper for regulation
• Community of customers
Stakeholders’ Group
Consumers’ Committee
Social Community

Contact
thomas.hipke@iwu.fraunhofer.de

May 25th 2021
Markus Maibaum, M. Sc. | Fraunhofer IWU
Roberto Seyfert, M. Eng. | Fraunhofer IWU
Remanufacturing of metal components:
RFID Data Storage

Marking of materials (Today)
https://www.verbraucherzentrale.de/wissen/lebensmittel/lebensmittelproduktion/recyclingcode-das-bedeuten-die-symbole-auf-verpackungen-11941
https://www.derwesten.de/panorama/kaum-jemand-weiss-es-das-bedeutet-der-geheimnisvolle-code-auf-plastikflaschen-id221114365.html
Sources:
metals
polymers
iron, steal
aluminium
• material marking is only a standard for purely material recycling of raw material
• There are many different chains and recycling routes

Intelligent Material Marking
• A novel approach is the marking or saving
of data for :
• ReUse
• Remanufacture or
• Refurbish
• In CarE-Service the aim is:
• collect much more information
connected to part or product
beside the single material
information.
• The focus is to have precise information
which are fitting to special processes for
reuse, remanufacture and refurbish
Full specifics
Main functionality
Base structure
Material
Dispositive effort
Minor
refreshment
Mayor
reforming
Full metal
value chain

 A possible Data Chip could be a RFID -Chip
 RFID tags can be sorted by :
 Frequency
 transmission speed
 Capacity
 prize
Research of data storage hardware and selection
Source: L-mobile.com ; https://www.smart-tec.com/de/auto-id-welt/nfc-technologie

Type Parameter Mandatory /
optional
Derived
from
Description
general Vehicle name mandatory OEM car name depending on OEM
general Part ID mandatory OEM unique part ID
general Year of
manufacture
mandatory OEM YYYY(.MM.DD)
general Part type mandatory OEM profile, structural part, deep
drawn part, etc.
general Material class mandatory OEM e.g. steel
general Material ident
number
mandatory OEM e.g. 1.0922
general Material norm mandatory OEM e.g. DIN EN 10268
general Material name mandatory OEM e.g. HC180Y+ZE
general Surface status mandatory OEM e.g. +AZ 150
 Writing Informations
data storage Hardware & Software in focus
 Put the written Chip on a
fitting place
 Reading Informations
 Example of potential useful
data for remanufacturing
processes.

 Smart and low cost solution for getting all required data through the live cycle of parts and
assemblies from OEM to remanufacturing companies
documentation for a fitting data storage concept
©
 Different RFID Chip
 Different RFID
Android Open
source software
(write and read)
Source: https://play.google.com/store/search?q=RFID&c=apps&hl=de&gl=US

Joining-Disassembly-Technology
May 25th 2021
Tibor Paizs | Fraunhofer IWU

Car Body Joining Technologies
Joining
DIN 8593 Part 0
Joining by Forming
DIN 8593 Part 5
Joining by Welding
DIN 8593 Part 6
Joining by Brazing
DIN 8593 Part 7
Bonding
DIN 8593 Part 8
MAG welding
laserbeam welding
laserbeam brazing
structural adhesive
resistance spot welding
self-pierce riveting
solid riveting
flow drill screw
Quelle: Audi AG
Quelle: Audi AG
Quelle: Audi AG
Quelle: Audi AG
Quelle: Audi AG
Quelle: Audi AG
Quelle: https://www.neumaier-industry.com/

Car Body Joining Technologies
steel
higher-strength steel
highest-strength steel
hot forming steel
resistance spot
weldings
structural adhesive
laserbeam welding
laserbeam brazing
MAG welding
Joining Technologies:
Not detachably
joining connections!
Quelle: Audi AG

Car Body Recycling
Car
com-
paction
Fractio-
nation
Melting down
and casting
Rolling of
coils
OEM /
Suppliers
Quelle:
Bundesarchiv
Bild
183-1988-0812-011
Quelle:
https://www.montanstahl.com/
Quelle:
https://www.gmh-gruppe.de/
Quelle:
https://www.wmu-bavaria.de/
Quelle:
https://www.alamy.de/

Car Body Recycling
Car
com-
paction
Fraction-
ation
Melting down
and casting
Rolling of
coils
OEM /
Suppliers
Remanufacturing by non-destructive
dismantling of brazed joint connections

Principle approach of the
Joining-Disassembly-Technology:
heat source
e.g.
laser beam
heat source
e.g.
laser beam
heat source
e.g.
laser beam
melted
solder
suction
melting
solder
single
parts
single
parts
final
product
brazing
Joining Disassembly
Brazed seam of CuSi3, CuAl8---
melting temperatur: 1040 °C
sheet steel (DC04, HX360, o.ä.)
melting temperatur: 1600°C
processing window:
1200°C…1500°C

Experimental equipment:
Laser processing optic with intelligent temperature control
semitransparent-mirror
Configuration of the laser processing optics with intelligent temperature control:
wave lenght of the
processing laser: 1050nm
wave length of the
pyrometer: 1700-2600nm

CFX calculation of the gas nozzle
melted
solder
suction
heat source
e.g.
laser beam
CFX calculation of the gas nozzle:
supersonic velocity!
supersonic shocks

configuration of the laser processing optics with intelligent temperatur control:
adapter for the fibre
of the pyrometer
DINSE wire feed
modul
pyrometer
high frequency laser
beam scanner
observation camera
air cleaner
protection of the
optical components
collimating lens
semitransparent-
mirror
focusing lens
adjustable gas
nozzle
position table for x
direction
Position table for z
direction
complete processing Optics

blowed out melted
soldered seam
process of disassembling with
a 1030 nm wavelength laser
processing zone

gas nozzle
(high pressure)
process in detail:

 the non-destructive desoldering of car-body parts is basically possible with
the technology that has been developed
 to increase the process speed, further process optimization are required
 a promising approach is the use of a high-speed thermal camera, which is
used for example for laser hardening
 further optimizations of the process are not possible within the scope of the
project
summery

reforming of sheet metal blanks
May 25th 2021
Rico Haase, M. Sc. | Fraunhofer IWU

Car Body Recycling
Car
com-
paction
Fractio-
nation
Melting down
and casting
Rolling of
coils
OEM /
Suppliers
Quelle:
https://www.spiegel.de/
Quelle:
https://www.dortmunder-hafen.de/

Concept:
Sheet Metal Re-Manufacturing Technology
Principle approach / Value Chain
Aim: Reduce ressource consumption by use of secondary raw material
(SRM) blanks instead of re-melting and roll-milling of recycled material.
Task: Consider mechanical, geometrical and other impacts
on SRM quality which is caused by the previous life cycle.

Concept:
Principle approach / Value Pyramid
Full specifics
Main functionality
Base structure
Material
Dispositive effort
Minor
refreshment
Mayor
reforming
Full metal
value chain
re-entry level of different recycling routes (WP 3.2)
State of Art
Re-Manu.
Spare parts
[lrp-autorecycling-
chemnitz.de]

Concept:
Process Chain
Low-Tech Approach:
- measurement of sheet metal thickness at single, discrete points
- extraction with handheld sheet metal cutter
 trimline depends on operator‘s skills
 no defined blank size achievable
 re-trim of blank required
- manual marking of blank (thickness/…)
Benefit: lowest fix cost for equipment
Issues: higher labour cost and additional
operations (defined trimming) necessary
Measurement
& Analysis of
wrecked car
Blank
extraction
Application of
tracking code
Sheet Metal
Forming
operation
Sale /
Assembly

Concept:
Process Chain
High-Tech Approach:
- measurement of sheet metal thickness at several points,
- curvature check by e.g. optical measurement system
- extraction with NC-controlled device:
 well-defined, repeatable trimline geometry
 direct use for forming operation
- automated marking and traceability of blank
Benefit: detailed information, repeatable quality,
quick processing and low labour cost
Issues: investment in automation required (SMM)
Measurement
& Analysis of
wrecked car
Blank
extraction
Application of
tracking code
Sheet Metal
Forming
operation
Sale /
Assembly

Concept:
Outlook / Upcoming aspects to consider in process planning of Re-Manufacturing technologies
- Impact of blank curvature
(generalized geometric influence)
- to wrinkling limit and
- to springback behaviour
 Establishment of a representative curvature factor
- summarizing the product of a double-curved blank shape
- allowing a separation of convex / concave bowls
- providing a quality parameter for SRM blanks
- Impact of previous forming and heat treatment
(generalized mechanical influence)
- to flow curve and
- to forming limit
Local Strain
Hardening
[Wikipedia:
Hyperbolische
Paraboloidschale]

Concept:
Forming operation details
Press: Müller-Weingarten CLDZ / 2500 kN
Tooling: deep drawing tool with
press-operated binder
Upper die: 1000 kN
250 mm stroke
Blank holder: 50…100…150 kN
15 mm stroke
delayed return

This project has received funding from the European Union’s Horizon 2020 research and
innovation programme under grant agreement No 776851
Circular Economy oriented services for re-use and remanufacturing
of hybrid and electric vehicles components through smart and movable modules
“Reforming technologies for re-manufacturing of sheet metal parts, metals disassembly and testing in
automotive”
25 May 2021

This project has received funding from the European Union’s Horizon 2020
research and innovation programme under grant agreement No 776851
Smart Mobile Module – Testing
Matthias Goetze
IMA Dresden

Content
• Where is IMA coming from?
• Role in the concept CarE-Service
• Characteristics in Metal Value Chain
• Smart Mobile Modules
• See you again soon

Where is IMA coming from?
Evaluation of capabilities of products to be alive under service conditions
In laboratories permanently observed state
using Non-destructive Inspections
Eddi current test
Visual inspection
Ultrasound
test
Magnetic particle
inspection

Role in the concept CarE-Service
Premise of Recovery
• Appropriate End of Life parts
• Proven characteristics
• Successfully passed
inspections
Challenge concerning
EV&HEVs
• Limited number of post-use
cars in this ramp-up phase
• Old fashioned car design

Role in the concept CarE-Service
Goals of future Metal Recovery
Enlarged sustainability by nearly level cycling
Less consumption of process energy
Find high valuable EoL parts dis-
tributed over many locations
High confidence in processing
result for each harvested part
Prosper Second Life Market
Re-soldering
Re-forming

Characteristics in Metal Value Chain
Which metal parts should be considered how?
Large faced sheets without kink
Without damage
Mechanical behaviour
Limited shapes
Unmountable parts
Without damage
Disconnectable joints
Without damage

Without damage
• Nondestructive Inspection
• Several kinds of Nondestructive Tests
• Hierarchically by effort, beginning
with visual inspection DIN EN 13018:2016
Findings?!
Rust
Scratch
Dent
Global Visual Inspection at Car Roof
Local
Visual
Inspection

Without damage
• Visual Inspection, standardised
Local Visual Inspection at Car Roof

Limited shapes
• Required minimum radii or maximal curvature respectively
• Shape analysis after reverse design by Digital Image Correlation (DIC)

Limited shapes
• Arrengement of stereoscopic sampling as data base for DIC

Mechanical behaviour
• Required deformation of former plastically formed sheets
• Residual capability of plastification proven by destructive Erichsen-Test
0.538
e1
0.000
dz = 12.46mm
DIC measurement Testing machine
Traveler
Car Roof

DIN EN ISO 12004-2 Forming Limit Curve
Mechanical behaviour with boundary conditions in circular economy
• Being comprehensive to First Life raw material
• Go easy with material for specimen extracted from a Second Life part
• Quick accessable significant information
Appropiate
Inappropiate
ε1
ε2

Smart Mobile Modules
Operational process
• Areal situation
• Work sharing
• Logisitic
Dismantler A
Dismantler B
Dismantler D
Dismantler C
Dismantler E

Disassembly Module
• DSS suggesting which components to disassemble
based on car sensors data, manufacturer product
data and market
• Disassembly guidelines
• Robotics cooperative disassembly
• Mechatronics tools
Smart Mobile Modules
An approach
• Mobile services tailor made for sophisticated recovery
• Advanced technologies for on-site disassembly and testing
• Operation on demand
Testing Module
Functional, geometric, mechanical and electric
testing methods and technologies for:
• Evaluation of re-usable parts
• Testing of components and parts for remanufacturing
• estimation of the type and content of high value-added
materials for recycling

See You Again Soon
21st July (Demonstration)
“New solutions for disassembly,
remanufacturing and testing automotive
metal parts”
In the Metal demonstration event,
Fraunhofer IWU will show the technolo-
gies for disassembling and remanu-
facturing the metal components at the
End-of-life of vehicles for producing new
parts.
“Automotive Polyamide Circularity?
Yes, it’s feasible”
In the Techno-polymer Demonstration
event RadiciGroup a project partner will
show the achieved results of recycling
the polyamide components used in the
vehicles through innovative technolo-
gies.
https://www.careserviceproject.eu/news-and-events/

CarE-Service Training on Metal Reforming by Fraunhofer

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