Definition State-of-art materials and coatings Technology based
on recent achievements in physics, chemistry and biology
Characterized by knowledge-intensity and process complexity
Involving first of all manufacturing of coatings and novel ceramic
& composite materials. High-Tech Materials &
Technologies5
Slide 6
Metals & Alloys Ceramics Polymers Composites High-Tech
Materials & Technologies Metals Ceramics Glass Composites
Polymers Cermets Glass-ceramics MCM MCMMetal composite materials
CCMCeramic composite material PCMPolymeric composite material
GCCMGlass-ceramic composite material FRGFiber-reinforced glass CCM
PCM GCCM FRG 6 Main material groups
Slide 7
Materials in a passenger car Passenger car compostion in 2001
[ACORD, Annual Report 2001] Ferrous + non-ferrous metals 68+8=76%
Polymers ~10% 7High-Tech Materials & Technologies ACORD report
from 2001 and BMW 7-series 2002-2008 Weight % of metals is
decreasing, growing importance of polymers BMW 7-series 2002-2008
Metals 48+24=72% Polymers ~15%
Slide 8
Trends in aviation High-Tech Materials & Technologies8
Slide 9
Materials in aviation Materials used in 787 Dreamliner, Boeing
[Boeing AERO magazine 2006 -
boeing.com/commercial/aeromagazine/articles/qtr_4_06 ] Materials
used in 787 Dreamliner, Boeing [Boeing AERO magazine 2006 -
boeing.com/commercial/aeromagazine/articles/qtr_4_06 ] 9High-Tech
Materials & Technologies
Slide 10
Materials in medical applications Numerous biocompatible
materials have found a place in medical applications Hip joints
Dental implants Heart valves etc. High-Tech Materials &
Technologies10 Ceramic Biocompatible coating (Ti-alloy)
Slide 11
Materials in building and mechanical engineering 11High-Tech
Materials & Technologies
Slide 12
Historical ages of materials STONE Cu (COPPER) BRONZEIRON
POLYMERS CERAMICS (STONE) STONE, WOOD COPPER, IRON POLYMERS
TAILORED MATERIALS (composite materials) 1 2 3 4 12High-Tech
Materials & Technologies
Main trends (1) Growing applications for ceramics, polymers and
composites use of metals is decreasing Growing multidisciplinary
collaboration (e.g. physics, chemistry, biology) synthesis and
processing of new materials 14High-Tech Materials &
Technologies
Slide 15
Main trends (2) Sustainable development Sustainable
technologies GRAPHICAL EXAMPLE FROM Mitsubishi Electric Group
Environmental Vision 2021 15High-Tech Materials & Technologies
in other words: REDUCE REUSE RECYCLE
Priorities of R&D (2) 6. Bioinspired materials learning
from nature Field known as: biomimetics, bionics, biomimicry Velcro
inspired from burdock Shark-skin inspired Speedo fastskins
Materials with lotus-leaf effect 17High-Tech Materials &
Technologies
Slide 18
Priorities of R&D (3) 7. Computational simulating (e.g.
Stress, crack propagation and molecular dynamics in nanoscience) A
three-dimensional model reproducing crack shapes. The colors
indicate the strength of local tensile stress. The crack opening is
exaggerated 100 times. Intricate crack shape typical of stress
corrosion cracking Itakura et al. (2005) Phys. Rev. E, 71
18High-Tech Materials & Technologies
Slide 19
Priorities (4) 8. Down-sizing (e.g. Moores law)...and sizing up
(selfassembly is very common in biological systems) THE NUMBER OF
TRANSISTORS PER CHIP DOUBLE EVERY 18 MONTHS Scheme of the
self-assembly of the Tobacco Mosaic Virus 19High-Tech Materials
& Technologies
Advanced metallic materials Metallic materials with superior
properties Superconductive NbTi, Nb 3 Sn, Nb 3 Ge Structural alloys
Neodymium rare-earth magnets (alloys of Nd, Fe and B) are strongest
known permanent magnets. Sm-Co magnets Mg- and Al-alloys with
superior properties, Al-metaglass, foams Ti-alloys with
thermomechanical properties, superalloys, maraging steels,
intermetallides, high-density alloys, shape-memory alloys
Biocompatible Ti-alloys Amorphous alloys with chemical and thermal
properties, Ni- and Fe aluminates 21High-Tech Materials &
Technologies
Slide 22
Advanced ceramic materials Oxide ceramics alumina, zirconia (Al
2 O 3 ) Non-oxide ceramics carbides, borides, nitrides, silicides
(Si 3 N 4, SiC, B 4 C) Low oxidation resistance, chemically inert,
electrically conducting, high thermal conductivity, extreme
hardness Manufacturing: Difficult & high cost Oxidation
resistant, chemically inert, electrically insulating, generally low
thermal conductivity, Manufacturing: alumina slightly complex &
low cost, zirconia more complex & higher cost Composites
particulate reinforced, combinations of oxides and non-oxides
22High-Tech Materials & Technologies
Slide 23
Advanced ceramic materials Special oxide ceramics
Electroceramics Non-oxide structural/tool ceramics Magnetic
ceramics Mechanical and thermal properties Chemical and thermal
properties Biocompatible ceramics Radiation resistance 23High-Tech
Materials & Technologies Optical ceramics
Slide 24
Ceramics for tools and parts Oxides: SiO 2, AlO 3, ZrO 2,
MgO-based mullite (3Al 2 O 3 *2SiO 2 ) Carbides: WC, Cr 3 C 2, TiC,
SiC, SiC, TiC SHS process (e.g. Si&C or Ti&C compounds)
Nitrides: Si 3 N-based, AlN Composites: Ti(C,N), SiAl(OH)
(sialon)-based 24High-Tech Materials & Technologies
Slide 25
Toughness-hardness of ceramics , kg/m 3 HV *, GPa K 1C, MPa*m
0,5 WC15800246 Si 3 N 4 (hot-pressed) 3200165 Si 3 N 4 (reactive
sintered) 3200822 SiO 2 (quartz) 270060,7 25High-Tech Materials
& Technologies Property Type of ceramic
Slide 26
Strength toughness of ceramics High-Tech Materials &
Technologies26
Powder technology in materials engineering 40High-Tech
Materials & Technologies
Slide 41
Powder metallurgy (PM) Associated primarily with automotive
industry (e.g. in 2004 an average car in USA had 19,5 kg of PM
details new engines 12 kg of PM details) Powders prealloyed
powders, fine dopants Ni (1 2) m Technologies powderforging (PF),
e.g connecting rods Materials - 7,75 g/cm 3 gears PM details
replace mechanically processed and moulded details PM Al- and
Ti-alloys replace casting and forging 41High-Tech Materials &
Technologies
Slide 42
PM/HIP Powder Metallurgy / High Isostatic Pressing Advantages:
Very fine microstructure and isotopic properties enables UT,
insucseptible to hydrogen brittleness (HISC) others close to
product-shape, flexible construction, good mechanical properties,
small series 1. Inert gas atomizing to produce powder 3. The
capsules are subjected to high isostatic pressure and high
temperature to obtain full density 2. Sheet metal capsules are
filled with the powder 42High-Tech Materials &
Technologies
Slide 43
SF /HIP Similar to PM/HIP, slab formation by spraying methods
43High-Tech Materials & Technologies
Slide 44
Processing of hybrid materials High-Tech Materials &
Technologies44 * SD Spray Deposition; HIP High Isostatic Pressing;
SHS Selfpropagated High-temperature Synthesis; SPS Spray Plasma
Sintering
Slide 45
Comparison of processing technologies of hybrid materials
CastingSDHIPSHSSPS Particle size, m Large500-1200
Sheet forming Sheet forming in superplastic state (SPF-process)
(> T recrystallication, possibility to achieve large deformation
values with one process, 1000 - 3000%) High-energy rate-forming
(HERF-process) also known as high- velocity forming (HVF) (at high
speed, no elastic after-effect) 53High-Tech Materials &
Technologies
Slide 54
Machining technology Integration of various cutting
technologies into machining centres. 54High-Tech Materials &
Technologies
Slide 55
High precision tools for microcutting, laserforming and welding
High-Tech Materials & Technologies55 3D-model of mold
insertLaser welding nozzle Sliced 3D-modelLaser welded part from
stellite
Slide 56
Comparison of high- and ultra-precision cutting technologies
DetailHigh-precisionUltrahigh-precision Accuracy < 1 m Submicron
Roughness, Ra~ 10 nm~ 1 nm Processing2D and 3D2D Production
scaleLong-runShort-run, 1-5 pc Materials No limitations, primarily
steels Non-ferrous metals, crystalline materials, semiconductors
56High-Tech Materials & Technologies
Slide 57
Intelligent tools Measuring process temperatures during
processing High-precision cutting e.g. intelligent drilling
/milling with programmable radial axis surface processing with a
computer numerical control (CNC) tool high-precision drilling
(accuracy 1 m) with punctual feed- rate, high L/d ratio High-Tech
Materials & Technologies57
Slide 58
Hard coatings in tooling traditional (Ti, Al)N HV 25 38GPa,
hardness in elevated temperatures, heat-resitance, thermal
conductivity multilayered alloyed nanostructured Nanostructured
coatings High-Tech Materials & Technologies58
Slide 59
Rapid prototyping (RP) CAD product (without machining) RP uses
virtual designs from CAD or animation modeling software and
transformes into thin, virtual, horizontal cross- sections and
glues them together layer by layer to form a prototype. High-Tech
Materials & Technologies59
Slide 60
Technologies of RP and base materials Prototyping
technologyBase materials Selective laser sintering Thermoplastics,
metal powders Fused deposition modeling Themoplastics, eutectic
metals StereolithographyPhotopolymer Laminated object
manufacturingPaper Electron beam meltingTitanium alloys 3D
printingVarious materials High-Tech Materials &
Technologies60
Slide 61
Rapid tooling (RT) Enables producing casting moulds for
complex-shaped parts (lower cost, faster manufacturing) Producing
of moulds by 3D printing using polymer or metallic powders.
High-speed production of Al- and non-ferrous castings with low
price
Slide 62
Rapid manufacturing (RM) Enables production of end-products
i.e. finished parts (sheet forming) it will never replace the mass
production technologies (injection and die casting, sheet
stamping); used mostly for production of parts with unique design
(average 2 pcs; total in 2001 1,72 million parts).
Slide 63
Additive Manufacturing Source: I. Gibson, D. W. Rosen, B.
Stucker, Additive Manufacturing Technologies, Rapid Prototyping to
Direct Digital Manufacturing. Springer, 2010.
Slide 64
Example: housings for electronic devices
Slide 65
Example: Architectural models
Slide 66
Specific processing / manufacturing technologies Electroerosion
process Electrochemical surface treatments Ultrasonic process
Concentrated energy flow processes electron beam laser plasma Water
jet (abrasive) 66High-Tech Materials & Technologies
Slide 67
Water & laser cutting 67High-Tech Materials &
Technologies