MICRO- AND NANOCRYSTALLINE CERAMIC - METAL FUNCTIONALLY GRADED MATERIALS

FOR TRANSPORT APPLICATIONS

Katarzyna Pietrzak

Grant agreement no.: 228869

SEVENTH FRAMEWORK PROGRAMMETHEME 4 – NMP: Nanosciences, Nanotechnologies, Materials and New Production Technologies

EC Brochure: NoEs in NMP Success Stories

KMM-NoE: ended 31.01.2009

international non-profit research association (AISBL) legally registered 13 March 2007 in Belgium for unlimited duration

Genesis:

KMM-NoE (FP6) → Results of investigations

KMM-VIN → Research and infrastructure potential

1 Idea of a new material (composition and morphology) for automotive and aerospace applications

2 Looking for end-users 3 Collaboration of scientist and industry partners

MATRANS !!!

OBJECTIVE

The main objective of the MATRANS is:

– to develop the series of advanced metal-ceramic FGM’s with enhanced, application-tailored properties targeted at specific applications in auto, aero-transport.

– to promote comprehensive approach combining material processing, characterisation and modelling.

FGM I: Al2O3-Cu

Al2O3-CuAg3Zr0.5

FGM II: Al2O3-NiAl

Al2O3-Ni3Al

FGM’s to be: DEVELOPEDCHARACTERISEDMODELLED

APPLLICATIONS

Valves

Brake disk

Thrusters

APPLI-CATION

SPECIFIC OBJECTIVE

FGM I

Al2O3-Cu,

Al2O3-

CuAg3Zr0.5

Aero-space

Thrusters

improved lifetime by 50% (to be tested via Low Cycle Fatigue tests) improved erosion resistance at inner hot wall by 10% (to be tested

with hot exhaust test) improved oxidation resistance at inner hot wall by 20 % (to be tested

by thermo-gravimetric analysis, TGA) improved high temperature strength of hot wall material system by

20% maintained high thermal conductivity >300W/mK of hot wall material

system lower thermal expansion than standard CuAg3Zr0.5 to reduce

thermomechanical stresses

Auto-motive

Brake disks

increased maximum material temperature in operation by 150 °C improved thermal conductivity by 40% reduced weight by 20% increased thermal shock resistance to avoid warping (to be tested by

tests of thermal shock and of high temperature deformation behaviour)

increased friction behaviour and wear resistance in operation temperature range (to be tested in flat on flat wear tests at service temperatures)

FGM II

Al2O3-NiAl,

Al2O3-Ni3Al

Auto-motive

Valves

improved high temperature strength for maximum temperature 900°C improved corrosion resistance (wet corrosion, high temperature

corrosion) by 30% reduced weight by 25% reduced friction torque in valve train by 10% wear resistance better than standard valvetrain by 40%

WP 1: Material requirements and preparation of starting materials T1-1 Definition of target applications, demonstrators and material requirements

T1-2 Preparation starting materialsWP 2: Processing of FGMs

T2-1 Powder metallurgy T2-2 Metal infiltration T2-3 SprayingT2-4 Processing of FGM demonstrators

WP 3: Characterisation of FGMs

T3-1 Nano/microstructure and residual stresses T3-2 Mechanical and physical properties T3-3 Resistance to service conditions

WP 4 ModellingT4-1 Modelling of FGM designT4-2 Modelling of FGM properties under service conditions T4-3 Modelling of uncertainties in FGM characterisation

WP 5: Demonstration T5-1 Testing/evaluation of thruster components T5-2 Testing/evaluation of valvetrain componentsT5-3 Testing/evaluation of breaking discs componentsT5-4 Life cycle analysis

WP 6: ManagementWP 7: Dissemination and networking

Workpackages

List of beneficiaries European Virtual Institute on Knowledge-based Multifunctional

Materials AISBL KMM-VIN Belgium Fraunhofer-Institut für Fertigungstechnik und Angewandte

Materialforschung FRAUNHOFER Germany National Technical University of Athens NTUA Greece Politechnika Wroclawska WRUT Poland Ustav Materialov a Mechaniky Strojov Slovenskej Akademie

Vied IMSAS Slovakia Cardiff University CU UK EADS Deutschland GmbH EADS Germany Centro Richerche FIAT CRF Italy Steinbeis Advanced Risk Technologies GmbH R-TECH Germany Technische Universitaet Kaiserslautern UNIKL Germany

KMM-VIN Belgium

Instytut Technologii Materialow Elektronicznych (ITME), Poland

Instytut Podstawowych Problemow Techniki Polskiej Akademii Nauk (IPPT), Poland

Instytut Metalurgii i Inzynierii Materialowej Polskiej Akademii Nauk (IMIM), Poland

Technische Universitaet Darmstadt (TUD), GermanyPolitecnico di Torino (POLITO), ItalyUniversita Politecnica delle Marche (UNIVPM), Italy

MATRANS Consortium (16 partners)

• ProcessingITME Warsaw (PL)IFAM Dresden (D)TU Darmstadt (D) IMSAS Bratislava (SK)NTUA Athens (GR)POLITO, Torino (IT)WTU, Wroclaw (PL)

• CharacterisationIMIM Cracow (PL)UNIVPM Ancona (IT)NTUA Athens (GR)IFAM Dresden (D)

• ModellingIPPT Warsaw (PL)UWC Cardiff (UK)TU Darmstadt (D)TU Kaiserslautern

• Industry/SMECRF Fiat (IT)EADS (D)Steinbeis R-Tech (D)

Duration: 3 years (2010-2013)EC grant: 3.6 M€START DATE: 1 Feb. 2010

Previous experience in FGM’s andPrevious experience in FGM’s and preliminary results preliminary results

Poluethylene foam Ceramic preform

Powder metallurgy

Metal infiltration

75%Al2O3-25%Me 25%Al2O3-75%Me

50%Al2O3-50%Me

Previous experience in FGM’s andPrevious experience in FGM’s and preliminary results preliminary results

Me

Al

Al2O3 Steel

Previous experience in FGM’s andPrevious experience in FGM’s and preliminary results preliminary results

THANK YOU FOR ATTENTIONTHANK YOU FOR ATTENTION