Leibniz Universität Hannover Faculty Faculty of Mechanical Engineering
Deutsch Contact Deutsch
Institute of Forming Technology and Machines
 
Institute for Forming Technology and Forming Machines Research
Current projects

Current research projects at the Institute of Forming Technology and Machines

Sheet metal forming

  • Investigation of current pulse and vibration superimposed embossing processes
    This research project investigates how the formability of sheet metal materials can be improved by combining electrical pulses with mechanical vibrations. The long-term goal is to develop models and process strategies to push the boundaries of cold sheet metal forming.
    Year: 2026
    Funding: Deutsche Forschungsgemeinschaft (DFG) – Projektnummer 556377329
  • Performance Enhancement of Manganese-Boron Steel Sheet Materials for Hot Stamping
    This research project focuses on developing a process chain to enhance the performance of manganese-boron steel sheet materials for hot stamping. Targeted surface decarburization to increase ductility is combined with resistance heating, which, compared to conventional furnace heating, increases the resulting strength while also being more energy-efficient. Both heat treatment processes are carried out in an oxygen-free atmosphere to prevent scale formation. Consistent transfer times are ensured by a robot.
    Year: 2025
    Funding: Deutsche Forschungsgemeinschaft (DFG) - Projektnummer 394563137
  • Wear model for the prediction of electrode lifetime in resistance heating for hot stamping
    The project investigates electrode wear in resistance heating and develops an analytical wear model. It extends existing models to include specific wear parameters and validates them. A novel wear test bench is used to define wear limits. The goal is to develop a model for predicting electrode failure in a wide range of production tasks.
    Year: 2025
    Funding: Deutsche Forschungsgemeinschaft (DFG) - Projektnummer 509812086
  • Process Technology for Forming Indentations with Horizontal Material Distribution
    The project investigates resistance spot welding on inclined joint planes where sliding motions interfere with weld bead formation. By developing asymmetric spot geometries, targeted mass distribution is achieved to compensate for these effects, thereby reducing weld defects, improving weld quality, and expanding the process limits.
    Year: 2025
    Funding: Europäische Forschungsgesellschaft für Blechverarbeitung e.V. (EFB) - Industrielle Gemeinschaftsforschung (IGF) – Fördernummer 01IF23916N
  • Method of producing grain orientation in electrical steel lamellae to reduce iron losses
    The magnetic core of electrical machines generally consists of stacked electrical steel laminations. According to the current state of the art, electrical steel laminations in electric motors are not grain-oriented, as the direction of the magnetic flux changes continuously during operation. The goal of the project is to improve the magnetic properties of the electrical steel laminations by creating a functionally appropriate grain orientation in the stator laminations, thereby reducing remagnetization losses and further increasing the efficiency of electric motors.
    Year: 2025
    Funding: Deutsche Forschungsgemeinschaft (DFG) - Projektnummer 561134853
  • Manufacture of assemblies in a servo-spindle press using position-controlled blind stud welding
    As part of the project, an integrated process chain is being developed that combines forming and blind stud welding. Welding studs are inserted directly during the forming process, resulting in one-piece, functionally integrated sheet metal components. The goal is to achieve robust, cost-effective processes with high component quality and industrial scalability.
    Year: 2025
    Funding: Central Innovation Programme for small and medium-sized enterprises (ZIM)
  • Increasing the strength of magnesium wrought alloy components by precipitation hardening II
    Magnesium sheets offer great potential for lightweight automotive construction, but have so far achieved lower strengths than aluminum alloys. In this follow-up project funded by the German Research Foundation (DFG), new Mg-Zn-Al-Ca-Mn alloys and process routes based on cast rolling and resistance heating treatment are therefore being developed to produce highly formable magnesium sheets with increased strength and reduced heat treatment times.
    Year: 2025
    Funding: Deutsche Forschungsgemeinschaft (DFG) – Projektnummer 60444535
  • Research and Development of Innovative Inverter Technology for Improved Integration of Renewable Energy Sources into Industrial Heating Processes
    This project aims to develop an inverter for heating systems, such as those required for press hardening. The key development focuses are: an adapted control speed, direct power supply from photovoltaic systems and energy storage devices (DC) to smooth out power peaks, and an integrated control system.
    Year: 2024
    Funding: Central Innovation Programme for small and medium-sized enterprises (ZIM)
  • Research project on the development of efficient, high-performance bipolar plates using the rubber drawing process for use in fuel cell systems and to prevent the “Snap Action” effect
    The ZIM project “BIP-GUM” investigates the rubber drawing process for the production of highly structured metallic bipolar plates for fuel cells and electrolysers. The goal is to increase performance through optimized channel layouts as well as cost-effective manufacturing with high dimensional accuracy. In addition, the “Snap Action” effect is reduced through adapted rubber dies, and an integrated punching concept for positioning holes is being developed.
    Year: 2024
    Funding: Central Innovation Programme for small and medium-sized enterprises (ZIM)
  • Energy-Efficient Improvement of Overall Component Performance in the Automotive Sector Warm Forming
    The goal of this research project is to improve the overall performance of crash-relevant body structural components through optimized tailored welded blanks. Energy-efficient rapid resistance heating is intended to enable the selective adjustment of high-strength and ductile properties with a graded transition between the hot-formed part, the weld seam, and the cold-formed material, reduce unwanted heat input, and significantly lower energy consumption compared to conventional roller hearth furnaces.
    Year: 2024
    Funding: Central Innovation Programme for small and medium-sized enterprises (ZIM)
  • Development and Characterization of Low-Friction Oxide Tool Coatings for Dry Aluminum Sheet Metal Forming
    The tribological challenges associated with deep drawing of aluminum necessitate optimization measures, which are primarily achieved through the use of lubricants. However, these come with environmental, health, and process-related drawbacks. The goal of this research project is therefore to develop oxide release layers to reduce friction and wear and enable economical, lubricant-free forming wherever possible.
    Year: 2023
    Funding: Europäische Forschungsgesellschaft für Blechverarbeitung e.V. (EFB) - Industrielle Gemeinschaftsforschung (IGF) - Fördernummer 01IF22659N
  • Lightweighting Potential of Formed FRP-Metal Hybrid Components
    Hybrid components are becoming increasingly important in automotive engineering: As durable, lightweight components with high specific material properties, they are replacing monolithic metal components. But how can hybrid structural components be manufactured for series production? The IFUM is investigating this as part of this research project in collaboration with the Institute for Joining and Welding Technology at the Technical University of Braunschweig.
    Year: 2023
    Funding: Europäische Forschungsgesellschaft für Blechverarbeitung e.V. (EFB) - Industrielle Gemeinschaftsforschung (IGF) - Fördernummer 01IF22651N

Bulk metal forming

  • EIS-KW - Development of an adaptive, energy-efficient and self-learning cooling and thermal management system for forging dies
    The focus of the project EIS-KW is the development of an adaptive, energy-efficient and self-learning cooling and thermal management system for forging dies. Die forging operations generate a substantial direct product carbon footprint at process temperatures of up to 1,250°C. The combination and application of additive manufacturing, conformal cooling and machine learning allows for a more sustainable and economically efficient design of forging processes.
    Year: 2026
    Funding: Europäischer Fond für Regionale Entwicklung (EFRE) der Europäischen Union und Land Nordrhein-Westfalen
  • Performance Enhancement of Components Made from Sintered Aluminium Chips
    This DFG project focuses on a resource-efficient recycling process of aluminium chips through direct sintering, to avoid the energy-intensive remelting of aluminium waste. This process route enables performance enhancement of chip-based components compared to conventional ones. The goal is to develop hybrid components with optimized properties and characterizable strengthening mechanisms.
    Year: 2025
    Funding: Deutsche Forschungsgemeinschaft (DFG) – Project No. 454199925
  • HoWZu – High performance materials of the future
    Starting on August 1st 2024, the IFUM has begun with the project „HoWZu – High performance materials of the future on. The project is funded by the European Union with the infrastructure fund EFRE as well as by the state of lower saxony.
    Led by: Julius Peddinghaus, M. Sc.
    Year: 2024
    Funding: European Regional Development Fund (ERDF) and State of Lower Saxony
  • Forging of α+ß titanium alloys with steel casing
    Titanium alloy products are currently mainly manufactured by machining. However, this leads to relatively large material losses. An alternative production method is the die forging process, whereby the forged titanium is more durable than the machined workpiece. Isothermal forging, which takes place in an inert gas atmosphere to prevent reactions with gases in the air atmosphere, is state of the art. Isothermal forging is therefore difficult to implement in terms of plant and process technology. The use of a steel capsule around the titanium alloy is intended to enable die forging without a protective gas atmosphere and isothermal forging with a low machining volume in order to ensure wider applicability.
    Year: 2023
    Funding: Deutsche Forschungsgemeinschaft (DFG) - Projektnummer 461918196
  • Transparent AI-supported process modeling in drop forging
    The goal of the project is to optimize a die forging process through the use of an AI data model for process modeling. It addresses the challenge of understanding complex interactions between various process parameters. By means of automated data collection, high-quality data are gathered to train the AI model, which will subsequently be capable of recognizing patterns and making predictions about quality characteristics based on process parameters.
    Year: 2022
    Funding: Deutsche Forschungsgemeinschaft (DFG) – SPP2422
  • Highly heat-resistant tool surface layers by extending the tailored forming technology to hot solid forming tools
    The objective of the project was the cost-effective manufacture of hybrid forming tools for thermomechanically highly loaded regions. By means of rotary friction welding and tailored forming, a wear-resistant nickel-based alloy was applied to hot-work tool steel in a load-adapted manner. Industry-relevant series forging trials demonstrated an almost complete suppression of tool wear.
    Year: 2022
    Funding: SFB 1153 – Transferprojekt T03
  • Novel combination of processes for the production of titanium aluminide-based components in an oxygen-free atmosphere
    Titanium aluminides (TiAl) are among the oxygen-affinous materials whose structural development and thus physical and technological properties depend heavily on the oxygen content. Due to their high heat resistance and very low density, they have high potential for application in the automotive, aerospace and aerospace industries. However, TiAl is difficult to process due to its brittleness, so that isothermal forging or hot isostatic pressing (HIP), which are complex in terms of process and system technology, are primarily used. Conventional powder metallurgical production, using die pressing and sintering, has so far led to inadequate results in terms of relative density as well as technological and physical properties due to impurities.
    Year: 2020
    Funding: Förderung: Deutsche Forschungsgemeinschaft (DFG) – SFB 1368 - Fördernummer 394563137
  • Determination of the deformation capacity and the resulting component properties during extrusion of serially arranged hybrid semi-finished products
    The subproject B3 deals with the extrusion of friction-welded hybrid semi-finished products made of steel-aluminum, steel-nickel-based alloy and steel-steel. During friction welding, different geometries of the end face are used in order to achieve a force and positive connection in addition to the material connection. Extrusion involves a variation of the extrusion process. To increase the stress caused by forming, a hollow shaft will serve as a demonstrator, which will be manufactured using various extrusion processes.
    Year: 2019
    Funding: Deutsche Forschungsgemeinschaft (DFG) – SFB 1153 – B3 – Fördernummer 252662854
  • Drop forging of coaxially arranged hybrid semi-finished products
    As part of the subproject B2, the drop forging of joined hybrid semi-finished products made from the material combinations steel-steel, aluminum-steel and titanium-aluminum is being investigated in the SFB 1153. The overarching goal is the process-reliable production of hybrid components through targeted control of the material flow. The focus is on developing suitable tool concepts and heating strategies for drop forging.
    Year: 2019
    Funding: Deutsche Forschungsgemeinschaft (DFG) – SFB 1153 – B2- Fördernummer 252662854

Forming machines

  • Set-up assistance system for transfer presses based on AI
    The research question to be answered as part of the project is whether process data combined with domain-specific knowledge can be processed and used in such a way that the gap between existing modeling approaches and reality can be closed with a measurement data-driven modeling of implicit process relationships using AI-based methods.
    Year: 2023
    Funding: Deutsche Forschungsgemeinschaft (DFG) – SPP2422 (Projektnummer 500936349)

Material characterization and simulation

  • Temperature-controlled hot forming for the manufacturing of complex lightweight components from tubes
    The project aims to develop a novel warm forming process using locally controlled temperature fields to manufacture complex lightweight components from thin-walled tubes. By enabling targeted control of material flow, more complex geometries can be achieved while avoiding folding defects. This allows multi-part components to be produced as single-piece solutions, reducing material usage, CO₂ emissions, and costs while improving component performance.
    Year: 2026
    Funding: Zentrales Innovationsprogramm Mittelstand (ZIM) - Förderkennzeichen: KK6041201CI5
    Duration: 2.5 Years
  • Coextrusion of steel–steel materials for manufacturing stress-optimised massive components
    As part of this research project, the composite forming process (compound extrusion) will be evaluated for the production of a load-adapted, lightweight-optimised steel-to-steel solid component, using a simplified universal joint yoke as an example. In addition, adapted thermal and mechanical process control should enable the elimination of time- and cost-intensive heat treatments, thereby reducing process and energy costs.
    Led by: Prof. Dr.-Ing. B.-A. Behrens
    Year: 2026
    Funding: Forschungsvereinigung Stahlanwendung e.V. - VP 13186
    Duration: 2 Years
  • Enhancing Resource Efficiency in Hot Bulk Forming Processes through Inline Defect Detection of Hot-Forged Components
    The aim of this transfer project from the Collaborative Research Centre 1153 is to develop a comprehensive quality control system operating within the forging cycle and under different hot-forging conditions, enabling the automated inline inspection of every component with regard to relevant geometric features. Based on the inline measurement, a real-time-capable surrogate model derives an adaptive control measures of process parameters in order to enhance process robustness and restore the production of conforming parts.
    Year: 2025
    Funding: Sonderforschungsbereich 1153 – Transferprojekt T07
  • Development of a controllable glaucoma drainage implant with anti-fibrotic properties - Glaukom-AF - TP LUH
    The aim of the project is to research a controllable glaucoma implant that solves known problems with current glaucoma implants. The implant is designed to open automatically to allow the drainage of ventricular fluid and to close again when the pressure decreases. If fibrotic tissue prevents automatic opening, an external actuator enables targeted, medically initiated opening of the valve.
    Year: 2025
    Funding: Europäischer Fond für Regionale Entwicklung (EFRE) und Land Niedersachsen (SER) Projektnummer: ZW 7- 87036273
  • Uncertainty Propagation in Powder Metallurgy Chain Process Modelling
    Stochastic uncertainties and their propagation are modelled and quantified for a powder pressing-sintering-sinter forging process chain. FE simulations and surrogate models are employed to analyse and validate the interactions between sub-processes with experimental data. The validated models enable an inverse optimization of the process, increasing robustness and energy efficiency in production of complex components with precise microstructural properties formed close to the final contour.
    Year: 2025
    Funding: Deutsche Forschungsgemeinschaft (DFG) – 558606079
  • FE-simulation of shear cutting of aluminium bars by considering the stress and temperature dependent effects in the plasticity and damage modelling
    In this research project, the elastic, plastic and damage behaviour of two high-strength aluminium alloys is characterised and modelled under varying temperatures, strain rates and stress states in order to simulate shear cutting of round bars using FE simulations. This will provide detailed insights into the interactions between process parameters and the resulting cut surface quality and enable numerical optimisation of the shear cutting process.
    Year: 2025
    Funding: German Research Foundation – Project number 538263864
  • Characterisation and modelling of medium Mn steel for the numerical simulation of hot sheet metal forming processes
    In order to fulfil the increasing requirements in the automotive sector regarding safety, range and CO2 emissions, new lightweight materials must be developed which show an optimal combination of strength and ductility. This research project is focused on the design of a process chain for hot forming of sheet metal components made of a novel medium Mn steel. Compared to established hot-forming steels, it offers process-related advantages such as a lower heating temperature and a lower cooling rate. Besides the identification of basic process parameters for optimised component properties, the focus lies on the characterisation and modelling of the flow, failure and transformation behaviour for the numerical process simulation.
    Year: 2024
    Funding: German Research Foundation (DFG) - Project number 505217238
    Duration: 27 Monate
  • Experimental and numerical modelling and analysis of microstructural residual stresses in hot formed components with targeted cooling
    Highly stressed components found e.g. in drives are manufactured by hot forming due to the resulting strength, reliability and cost effectiveness. Currently manufacturing processes aim to lower the remaining residual stresses since they can lead to early component failure. However, research studies showed that especially residual stresses with a negative sign can improve the component performance. Therefore, the aim of this research project is to induce beneficial compressive residual stresses in component-like samples with targeted cooling of the forming heat. Optimal process parameters are determined using FE simulations and the results are experimentally validated in fatigue tests.
    Year: 2024
    Funding: German Research Foundation (DFG) - Project number 530125423
  • Experimental and numerical analysis of morphological changes regarding nonmetallic inclusions in the steel matrix during hot forming
    Manganese sulphides (MnS), which form in manganese-containing steels, reduce the strength of the material. The shape of the sulphides plays a particularly important role, as flattened MnS inclusions act as internal notches. The resulting morphology of manganese sulphides depends on many factors of the forming process and will be analysed in more detail in this project. Extensive experimental investigations and detailed numerical simulations using representative volume elements will provide a deeper understanding, enabling better evaluation of the failure behaviour of MnS inclusions in the future.
    Year: 2024
    Funding: German Research Foundation (DFG) - Project number 461157061
  • Modelling of material failure in press-hardened steel for shear cutting taking into account pre-damage in the austenitic state
    The research project aims to model the two-stage shear cutting of 22MnB5 using numerical simulations, taking into account the deformation and failure behaviour at varying temperatures. Particular attention is paid to the pre-damage in the austenite area and its influence on the failure at room temperature.
    Year: 2024
    Funding: Deutsche Forschungsgemeinschaft - Projektnummer: 511827546
  • Local heat treatment in draw bending for the requirement-oriented production of profile components
    The project focuses on advancing incremental bending with integrated heat treatment for the production of adaptable profile components. The objective is to manufacture stress-optimised U-profiles with variable cross-sectional geometry and additional form elements. A wear model aims to improve the prediction accuracy of die lifespan.
    Year: 2023
    Funding: German Research Foundation (DFG) – Project number 507245889
  • Component variation in the manufacture of hybrid composites by free kinematic forming
    Hybrid lightweight material construction enables new design possibilities for structural components. Free kinematic forming is used to research the best possible combination of different materials under economical production conditions. Moreover, the influence of the component geometry is methodically solved by adapting the tool path and generating a tool geometry for component variants
    Year: 2023
    Funding: German Research Foundation (DFG) - Project number 318620418
  • Substitution of conventional die lubrication in cold forging by using self-lubricating powder metallurgical blanks II
    In this project, the novel approach of using self-lubricating powder metallurgical (PM) semi-finished components to replace conventional phosphating process is investigated. The objective is to optimise the critical balance between the porosity and the formability of the PM components. The forward rod extrusion process is investigated numerically and experimentally to analyse effectiveness of the novel approach.
    Year: 2023
    Funding: Deutsche Forschungsgemeinschaft (DFG) – 264818458
  • Experimental-numerical method for predicting damage and failure of joining zones in hybrid semi-finished products during forming
    In the third funding period of SFB1153, subproject C01 is dedicated to predicting component failure using artificial intelligence methods. To this end, various model architectures are trained with numerically generated data in order to accurately predict failure-relevant variables within the joint zone.
    Year: 2023
    Funding: Deutsche Forschungsgemeinschaft (DFG) – SFB 1153 TP C1 - Fördernummer 252662854
  • Determination of the heat transfer coefficient for the numerical design of compound forging processes
    Composite forging of dissimilar materials poses a challenge with regard to the different forming temperatures of the materials. The temperatures present at the contact surfaces of the semi-finished products have a significant influence on the forming result and the formation of intermetallic phases. This project aims to identify the local temperatures of the semi-finished products and dies by determining realistic heat transfer coefficients under process relevant conditions. Using these, the forming result of the compound forging process can be predicted numerically more accurately.
    Year: 2022
    Funding: German Research Fundation (DFG) – Project number 496068488
    Duration: 2 Jahre
  • Collaborative Research Centre 1153 "Process chain for the production of hybrid high-performance components through tailored forming"
    The goal of the third funding period in subproject A01 of CRC 1153 is to increase process reliability and enhance the robustness of the tailored forming process chain for the production of hybrid components. To achieve this, the research focuses on process development and modelling are expanded to include the new focus on process monitoring.
    Year: 2019
    Funding: German Research Foundation (DFG) – CRC 1153 TP A1 - Project number 252662854
  • Numerical modelling of hot forming with integrated heat treatment taking into account the influence of variable stress states on the transformation-plastic strain behaviour
    The aim of this project is the development of a thermo-mechanical-metallurgical coupled material model. The focus is on consideration of a transformation plasticity effects based on microstructure evolution in numerical process simulation. Taking into account thermal, mechanical and metallurgical effects and interactions increase the numerical prediction quality of residual stresses and distortion development as well as optimise process design for forming of distortion-prone solid parts.
    Year: 2019
    Funding: German Research Foundation (DFG) - Project number 212963651

Last Change: 12.05.26 Print

Contact us
Contact