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Lightweight Construction and Hybrid Materials: New Joining Technologies for Stable, Lightweight Components

Lower fuel consumption, fewer emissions, and increased payloads – the development of lightweight and stable structures is a key aspect of more efficient aircraft and space systems. Hybrid materials that combine plastics and metals offer a promising solution. To ensure reliable bonding of these materials, Fraunhofer ILT has developed joining technologies that enable mechanically robust and long-term stable connections, such as laser structuring for plastic-metal hybrid components. In this process, the metal surface is first structured with a laser to create micropores. These are then filled with plastic, resulting in an especially strong and durable bond.

Through precise laser structuring, we can significantly improve adhesion between metal and plastic, enabling the development of hybrid components that are both lighter and mechanically more robust.

Dr. Alexander Olowinsky, Head of Joining and Separating at Fraunhofer ILT

This enables the production of metal-plastic connections with the necessary structural strength for use in wings, fuselage structures, and engine components.

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Laser transmission welding for fiber-reinforced composites is also an important innovation for modern lightweight construction. In this process, the joining zone absorbs the laser beam, enabling heat-resistant plastic components to be securely bonded with fiber-reinforced composites. The method improves the mechanical strength and durability of these materials while reducing manufacturing costs.

The advantages of processing hybrid materials with laser technology are: weight reduction, increased strength and durability of connections, cost savings through low-maintenance joining methods, and laser-based repair techniques.

Dr. Alexander Olowinsky, Head of Joining and Separating at Fraunhofer ILT

Additionally, the Laser Institute is researching LMD with aluminum alloys. "Since aluminum has high thermal conductivity, welding is traditionally a challenge," says Thomas Schopphoven. "The adapted LMD process enables high-strength, precise welds that do not unnecessarily stress the material. This technique is particularly suitable for weight-saving structural elements in aircraft and spacecraft." With these developments, Fraunhofer ILT contributes to making the aerospace industry more efficient, sustainable, and economical.

Laser Technology for Satellite and Atmospheric Research

The precise acquisition of atmospheric data and the advancement of satellite-based technologies are essential for modern communication systems, climate research, and Earth observation. Laser systems offer significant advantages over conventional methods: they enable high-resolution, selective measurements of specific molecules, precise determination of airflows, and secure data transmission in quantum communication. In several projects, Fraunhofer ILT is developing customized laser systems for use in satellites and ground-based installations to meet these challenges.

LIDAR (Light Detection and Ranging) technologies have proven to be effective tools for studying atmospheric processes. In collaboration with the Leibniz Institute for Atmospheric Physics (IAP), Fraunhofer ILT has developed powerful LIDAR systems for climate research measurement campaigns in recent years. These systems use high-energy UV lasers that enable daylight-capable measurements of aerosol and trace gas distributions. In addition to ground-based systems, Fraunhofer ILT is researching aircraft- and satellite-based LIDAR technologies relevant for future Earth observation satellites. The focus is on developing compact, high-performance laser systems with excellent beam quality, minimal energy consumption, and high reliability.

An outstanding example is the MERLIN mission (Methane Remote Sensing LIDAR Mission), a German-French cooperation for the global monitoring of methane emissions. Methane, as a greenhouse gas, is about 25 times more harmful to the climate than CO₂ and has a significant impact on climate change.

The Fraunhofer ILT, in collaboration with Airbus Defence and Space, developed a highly stable transmitter for a LIDAR system capable of detecting methane in the Earth's atmosphere.

Dipl.-Ing. Hans-Dieter Hoffmann, Head of Laser and Optical Systems at Fraunhofer ILT

"This system makes it possible for the first time to map methane emissions from natural and man-made sources with high spatial resolution," explains Dipl.-Ing. Hans-Dieter Hoffmann, head of the Laser and Optical Systems department at Fraunhofer ILT.

Another research area of the Nonlinear Optics and Tunable Lasers group, headed by Dr. Bernd Jungbluth, focuses on components and assemblies for quantum communication. This includes sources for entangled photons suitable for use in space. For their satellite-compatible implementation, Fraunhofer ILT developed the optomechanical platform ILT OPTOMECH.

Innovations for the Next Generation of Aerospace

Corrosion and material fatigue are general challenges in aerospace, as components must withstand extreme conditions such as high temperatures, vibrations, and harsh environments. Fraunhofer ILT is developing laser-based coating technologies that reduce component wear and extend their service life. This includes the LMD process as well as thin-film technologies. The focus is particularly on thermal barriers for engines and high-strength protective coatings for aircraft and satellite components.

Targeted laser treatments such as LMD coating and heat treatment can be used to adapt material properties to ensure greater resistance to corrosion and mechanical wear. This not only enhances safety but also reduces maintenance costs and extends the service life of critical systems.

Another approach for the advancement of materials and efficient concepts in the aerospace industry is further digitization and increased use of artificial intelligence (AI). This includes automated defect detection in manufacturing, optimization of laser-based joining techniques for new material classes, and the integration of AI into process monitoring.

With its interdisciplinary research approach, Fraunhofer ILT, as the largest European research center in laser technology, is a key player in innovations for aerospace. The institute's developments contribute to realizing more efficient, sustainable, and high-performance systems for the future.