How is digitalisation revolutionising the automotive industry, particularly in the realm of lightweighting? In this episode of the Greener, Smarter, Lighter Podcast, we explore this question with insights from Michael Luke from Fraunfofer IWM and George Zaverdinos from DELTA MPIS.

Host
Hello listeners, and thank you for tuning into our series on Automotive Lightweighting and its future impact on the automotive industry. In today’s episode, we are joined by two experts in digitalisation related to lightweighting. They will shed light on digital transformation in design and manufacturing, digital twin technology, and materials traceability to foster circularity. Stay tuned as we welcome Michael Luke and George Zaverdinos.

Michael Luke is a materials engineer by training, currently working at the Fraunhofer Institute for Mechanics of Materials. He heads the department of component safety and lightweight construction, representing the Lightweight Alliance of 14 institutes of the Fraunhofer Gesellschaft. George Zaverdinos holds a master’s degree in chemical engineering and computational mechanics. He has extensive expertise in composite material mechanics through simulation from his career in academia and industry. George currently focuses on computational failure mechanic applications, model-based design, and cyber-physical systems for digital twin development.

Host:
Michael, can you introduce our listeners to how digitalisation is impacting the manufacturing industry and specifically, automotive?

Michael Luke:
Digitalisation is a huge enabler, allowing us to collect and analyse data at different levels, from manufacturing processes to component performance. This capability accelerates design processes and is crucial due to regulations like the end-of-life vehicle directive, which requires OEMs to consider recycling and reuse.

George Zaverdinos:
Digitalisation is crucial for the industry, minimising costs of repeated testing procedures and predicting the performance of parts. Adopting digital tools helps industries get closer to reality.

Host:
What does digitalisation facilitate that was not possible 10 years ago? Is it a game changer?

Michael Luke:
Yes, it helps us understand manufacturing processes in detail, allowing us to adjust to material deviations and ensure component performance meets requirements.

George Zaverdinos:
Digitalisation enables the development of data-driven models like digital twins, describing physical assets in real-time without extensive sensor installations. This was not possible 10 years ago due to the lack of advanced machine learning.

Host:
George, can you introduce the concept of digital twinning and its impact on testing, optimizing, and overall efficiency in the automotive domain?

George Zaverdinos:
Digital twins create virtual representations of physical assets, monitoring critical parameters like stress distributions. They can be physics-based or data-driven, improving prototyping and performance prediction.

Michael Luke:
Digital twins provide information over time, reflecting the condition of components throughout their lifecycle. They can also include layers like material procurement and manufacturing details.

Host:
Could you tell us about the latest applications of this technology in your projects?

George Zaverdinos:
We developed digital twins for a prototype rotary engine and the manufacturing process of filament winding, enhancing defect monitoring from the beginning.

Michael Luke:
In Germany, we’re working on the “Material Digital” initiative, creating use cases for various materials and technologies, linking them in a knowledge graph for better assessment.

Host:
How can digitalisation increase circularity and sustainability within material traceability?

Michael Luke:
Digitalisation helps trace materials used in components, combining this with carbon footprint data. Ontologies and knowledge graphs can answer questions about the component’s lifecycle and potential for reuse.

Host:
What are the barriers to the implementation of digital twinning and other technologies?

George Zaverdinos:
Acceptance is a significant barrier, as industries tend to trust established processes. The European Union’s support for digitalisation initiatives is crucial.

Michael Luke:
Combining different areas of expertise, like informatics and manufacturing, is challenging. Digitalisation requires more effort in documentation and standardisation but can be implemented gradually.

Host: Any exciting projects in your pipeline?

George Zaverdinos: We are developing a lightweight hydrogen storage tank for aviation, optimising its geometry and operation pressure.

Michael Luke: We are creating use cases for “Material Digital,” focusing on predicting the fatigue behaviour of high-strength steels based on microstructure and chemical composition.

Thank you, gentlemen, for your insights. Listeners, thank you for tuning in. Join us next week as we dive deeper into the topic of circularity in automotive lightweighting. This podcast is in collaboration with the SALIENT Horizon Europe project and the grant agreement 1010 69 600.

Learn more about the SALIENT project here       

Visit Fraunhofer IWM here

Visit DELTA MPIS here 

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