Universität Stuttgart
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Item Open Access Design of fiber-composite/metal-hybrid structures made by multi-stage coreless filament winding(2022) Mindermann, Pascal; Müllner, Ralf; Dieringer, Erik; Ocker, Christof; Klink, René; Merkel, Markus; Gresser, Götz T.The methods presented in this study assist in fabricating load-bearing structures with high mass-specific mechanical performance at various scales. Possible applications include primary and secondary structures in engineering, architecture, automotive, or aerospace industries.Additive manufacturing processes, such as coreless filament winding with fiber composites or laser powder bed fusion with metals, can produce lightweight structures while exhibiting process-specific characteristics. Those features must be accounted for to successfully combine multiple processes and materials. This hybrid approach can merge the different benefits to realize mass savings in load-bearing structures with high mass-specific stiffnesses, strict geometrical tolerances, and machinability. In this study, a digital tool for coreless filament winding was developed to support all project phases by natively capturing the process-specific characteristics. As a demonstration, an aluminum base plate was stiffened by a coreless wound fiber-composite structure, which was attached by additively manufactured metallic winding pins. The geometrical deviations and surface roughness of the pins were investigated to describe the interface. The concept of multi-stage winding was introduced to reduce fiber–fiber interaction. The demonstration example exhibited an increase in mass-specific component stiffness by a factor of 2.5 with only 1/5 of the mass of a state-of-the-art reference. The hybrid design approach holds great potential to increase performance if process-specific features, interfaces, material interaction, and processes interdependencies are aligned during the digitized design phase.Item Open Access Self-cooling textiles : substrate independent energy-free method using radiative cooling technology(2024) Zimmermann, Lea; Stegmaier, Thomas; Kaya, Cigdem; Gresser, Götz T.Due to climate change, population increase, and the urban heat island effect (UHI), the demand for cooling energy, especially in urban areas, has increased and will further increase in the future. Technologies such as radiative cooling offer a sustainable and energy-free solution by using the wavelength ranges of the atmosphere that are transparent to electromagnetic radiation, the so-called atmospheric window (8-13 µm), to emit thermal radiation into the colder (3 K) outer space. Previous publications in the field of textile building cooling have focused on specific fiber structures and textile substrate materials as well as complex multi-layer constructions, which restrict the use for highly scaled outdoor applications. This paper describes the development of a novel substrate-independent coating with spectrally selective radiative properties. By adapting the coating parameters and combining low-emitting and solar-reflective particles, along with a matrix material emitting strongly in the mid-infrared range (MIR), substrate-independent cooling below ambient temperature is achieved. Moreover, the coating is designed to be easily applicable, with a low thickness, to ensure high flexibility and scalability, making it suitable for various applications such as membrane architecture, textile roofs, or tent construction. The results show a median daytime temperature reduction (7 a.m.-7 p.m.) of 2 °C below ambient temperature on a hot summer day.Item Open Access Validation of the manufacturing Methodology of prestressed fiber-reinforced polymer concrete by the variation of process parameters(2023) Engert, Michelle; Werkle, Kim Torben; Wegner, Robert; Born, Larissa; Gresser, Götz T.; Möhring, Hans-ChristianPolymer concrete has proved to be advantageous in machine building for many years thanks to its excellent damping properties. Until now, its use was limited to machine beds due to its comparatively low tensile strength. Its use in moving structural components has not been possible until now. Recent research results have shown that this challenge can be met by integrating prestressed carbon fibers. Until now, the production of samples out of prestressed fiber-reinforced polymer concrete has been carried out according to fixed specifications. It is not yet clear whether these specifications are suitable to fully exploit the potential of the material. Samples manufactured to these specifications show at least a large scatter in bending stiffness. Within the scope of this paper, the existing manufacturing process is validated by the variation of process steps. Specifically, this involved the use of a shaker, variation of the dwell time in the mold, variation of the resin content, and the procedure for impregnating the fibers. The characterization of the samples showed that the scatter could only be reduced by increasing the dwell time. However, this leads to a decrease in bending stiffness and, thus, is not suitable for further improvement of the novel material.Item Open Access Development of an impregnation end-effector with fiber tension monitoring for robotic coreless filament winding(2021) Mindermann, Pascal; Bodea, Serban; Menges, Achim; Gresser, Götz T.The manufacturing process of robotic coreless filament winding has great potential for efficient material usage and automation for long-span lightweight construction applications. Design methods and quality control rely on an adequate digital representation of the fabrication parameters. The most influencing parameters are related to the resin impregnation of the fibers and the applied fiber tension during winding. The end-effector developed in this study allows efficient resin impregnation, which is controlled online by monitoring the induced fiber tension. The textile equipment was fully integrated into an upscaled nine-axis robotic winding setup. The cyber-physical fabrication method was verified with an application-oriented large-scale proof-of-concept demonstrator. From the subsequent analysis of the obtained datasets, a characteristic pattern in the winding process parameters was identified.Item Open Access The influence of background materials on the radiative cooling performance of semi-transparent and opaque textiles : a theoretical and experimental analysis(2024) Zimmermann, Lea; Aili, Ablimit; Stegmaier, Thomas; Kaya, Cigdem; Gresser, Götz T.This paper investigates the theoretical and experimental cooling performance of textile materials utilizing radiative cooling technology. By applying Kirchhoff’s law, the emissivity of surfaces is determined, revealing that materials with high transmission values can achieve comparable cooling performance to those with high reflection values. Notably, materials exhibiting moderate reflectance and transmittance in the solar range tend to absorb minimal solar radiation, thus offering high theoretical cooling performance. However, practical applications like building envelopes or clothing present challenges due to the impact of background radiation on overall cooling capacity. Despite their intrinsic cooling properties, a significant portion of solar radiation is transmitted, complicating matters as the background can significantly affect overall cooling performance. This study provides a solution that accounts for the influence of background materials. Based on spectral data, various background materials and their impact on different semi-transparent comparison materials can be considered, and cooling performance can be simulated. This enables the simulation of cooling performance for various application scenarios and facilitates comparisons between transparent, semi-transparent, and opaque textile materials.