research unit of advanced, composite, nanomaterials ...€¦ · research unit of advanced,...

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Work Group Meeting 16 June 2017, Prague, Czech Republic

Research Unit of Advanced, Composite, Nanomaterials & Nanotechnology

National Technical University of Athens

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Description The National Technical University (NTUA) is the oldest and most prestigious educational institution of Greece in the field of technology, and has contributed unceasingly to the country's scientific, technical and economic development since its foundation in 1836. It is closely linked with Greece's struggle for independence, democracy and social progress. In Greek, NTUA is called the "Ethnicon Metsovion Polytechnion" which stands for National Metsovion Polytechnic. It was named "Metsovion" to honor the donors and benefactors Nikolaos Stournaris, Eleni Tositsa, Michail Tositsas and Georgios Averof, all from Metsovo, a small town in the region of Epirus, who made substantial donations in the last half of the 19th century.

Facts and figures:

9000 undergraduate students, 5-years curriculum 1500 graduate students 550 faculty members 150 laboratory personnel 260 administrative staff 20 Interdisciplinary Postgraduate Courses

Host institute – National Technical University of Athens

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NTUA – Academic Structure

Civil Engineering

Mechanical Engineering

Electrical & Computer

Engineering

Architecture

Chemical Engineering

Rural & Surveying

Engineering

Naval Architecture & Marine

Engineering

Mining & Metallurgical

Engineering

Applied Mathematical &

Physical Sciences

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Connects research carried out by NTUA with the needs and interests of the producing business

Enriches the educational process with relevant experience gained from this connection

(LTCP) - www.ltp.ntua.gr/

NTUA

LTCP

Lavrion Technological & Cultural park

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People

72 faculty members

800 undergraduate students, 160 freshmen each year

400 doctoral candidates

150 graduate students, in two Interdisciplinary

Postgraduate courses on

1) Computational Mechanics

2) Materials Science and Engineering

Structure (Departments)

I. Chemical Sciences

II. Process Analysis and Plant Design

III. Materials Science and Engineering

IV. Synthesis and Development of Industrial Processes

Ranked 101-150 worldwide, 30-40 in Europe,

by QS World University Rankings 2012

http://www.chemeng.ntua.gr

School of Chemical engineering

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Head : Professor Costas Charitidis

People :

• 5 Professors

• 4 Post Doctoral Researchers

• 5 Researchers

• 9 PhD & MSc students

The "Research Unit of Advanced, Composite, Nano Materials & Nanotechnology", R-NanoLab is situated at the School of Chemical Engineering (Department of Materials Science and Engineering) of National Technical University of Athens (NTUA). It is established since 2006; its research group has extensive experience in Design, Production and Characterization of Advanced-, Composite- and Nano- Materials.

Clusters :

• The European Materials Characterization Cluster

• The European NanoSafety Cluster

• The European Materials Modelling Council

• The European Carbon Fibre & Advanced Composites

Technology Cluster

• The European Engineering and Upscaling Cluster

• European Pilot Production and Networking

R-Nano in a nutshell - nanolab.chemeng.ntua.gr

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• Carbon based micro(nano)structures (CNTs, CNFs, CFs, graphene etc)

• Core and Core/Shell nanoparticles

• Polymer matrices (epoxy, PDMS, etc)

• Synthesis and characterization of novel composite materials

• Materials modeling (atomistic, mesoscopic, macroscopic)

• Innovative measurement techniques in the field of materials science

• Composite materials for the construction industry

• Biomaterials

R-Nano | main research activities

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• Carrier Frame and Brake system construction (increase accuracy of applied tension - accomplished)

Stabilization process of PAN fiber • continuous process of fiber

• set up of different temperature profiles (e.g. 180/220/260/290°C)

• set up of different tensions profiles (e.g. 7/7/5/3.5N)

•minimize deviation of real and set values (±0.5oC and ±0.1N)

• production rate 0.4 - 4.0m/min • fully automated system

R-Nano | Continuous stabilization line

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R-Nano | pilot melt spinning line Installation of Compressed Air units & network Twin screw extruder, volumetric hoper and multifilament

Air quench cabinet, winding and take-up system

• Compressed air supply vital for system operation • Installation of 16.8m3/h air supply at 6 bar pressure for

multifilament operation • Soundproof vertical air receiver compressor • Installation of 60m3/h air supply at 11 bar pressure for reversed

venturi air gun • TUV certified CE 97/23

Spin fibers extrusion downwards through vertical cooling tunnel. Each godet temperature Speed of each godet and coupling factor are individually programmable Stretching ratio from godet to godet is also programmable

• Lab Extruder Ø20 mm with an overall processing length of 25 L/D

• Integrated melt pump (gear pump) and melt valve as a bypass system

• Output range: 0.3 up to 2.5 kg/h with extruder Ø 20 mm • Production rate 100 - 500 m/min • Temperature control for each godet (4 x) • Speed control for each godet (4 x) • Stretching ratio from godet to godet (4 x)

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Corrosion testing

A complete array of conventional electrochemical techniques and spatially resolved electrochemistry is made available for full assessment of the corrosion resistance.

Concerning passivation, corrosion onset and corrosion healing, Electrochemical Impedance Spectroscopy, DC Polarisation, Scanning Vibrating Electrode Technique and Localized Electrochemical Impedance Spectroscopy will be used to study the response of fine graded intermetallic base parts.

Atomic Force Microscope equipped with an extra electrochemical cell will be used to monitor in-situ topographical changes

due to electrochemical reactions.

R-NANO Research Unit | NTUA - Facilities

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Overlapping roles of nano-indentation, micro-indentation and tensile tests.

Elastic and plastic

response

Elastic response

Nano-indentation

Tensile test

Plastic response

Micro-indentation


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Lower heating stage

Upper heating stage Upper heating stage

Sample mounting stage

Upper heating stage

Lower heating stage

Sample

Transducer

Indenter tip holder

Protective cap

Indenter probe

xSol High Temperature Stage, Hysitron Inc. Measurements from RT 800C at stable temperature conditions

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Lower heating stage

Granite base

Transducer

Automated

X-Y stage

Protective cap Optical lens

Optical fiber

Sample mounting

stage

Cooling liquid

hose

CCD camera

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R-NANO | Running projects

A novel process for manufacturing complex shaped

Fe-Al intermetallic parts resistant to extreme environments

The research leading to these results has received funding from European Community’s HORIZON 2020 framework programme for research and innovation under GA Ν◦ 689510

equ

inox-p

roject.eu


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equinox-project.eu


Outline

o The consortium

o Objectives and impacts

o State of the Art

o Methodology

o Work Package structure

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equinox-project.eu


Consortium - Responsibilities

Participant No * Participant organisation name Country Type Responsibilities

1 National University of Athens (NTUA) GR RTO Mechanical testing

2 TEKON DE SME Demonstrators

3 Dr. Kochanek Entwicklungsgesellschaft (KE) DE SME Preforms

4 IMDEA ES RTO Infiltration

5 TU-Liberec (TUL) CZ RTO Heat treatment,

Microstructure

6 Access DE RTO Modeling, Simulations

7 Open Source Management (OSM) UK SME Dissemination

8 CES Operations (CES) NO SME Demonstrators

9 Freni Brembo S.p.A (BREMBO) IT Industry Demonstrators

10 Yuzhnoye (YUZ) UKR Industry Demonstrators, Preforms

11 Innovation in Research and Engineering Solutions (IRES) BE SME LCA, SbD principles

Prof. C.A. Charitidis (NTUA): Coordinator

Dr. W. Kochanek (KE): Technical coordinator

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equinox-project.eu


Consortium

Industry (2)

SME (5)

NTUA

Institute (4)

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equinox-project.eu


Main objective

The main objective of EQUINOX is :

to develop a novel process that allows to substitute Critical Raw Materials

(CRMs) based stainless steel parts used in high volume end consumer

products such as in the lock industry, electronics, process and

automotive industry with a new class of highly advanced ductile Fe-Al

based intermetallics produced by a novel near net shape technology.

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The main objective is supported by the following specific objectives : 1. Produce extremely fine grained FeAl-Material of high ductility via reactive infiltration of

porous iron preforms with liquid Aluminum

2. Understand how ultrafine porous iron structures of complex 3D-shape can be tailored to be used as optimized preforms for reactive infiltration of liquid Al-alloys

3. Develop a reactive infiltration process by using two different techniques: suction and centrifugal casting

4. Simulate reactive infiltration process by physically based multi-scale models based on StarCast and MICRESS

5. Optimize mechanical properties of EQUINOX material with respect to microstructure based on process conditions and consecutive heat treatment

6. Scale up the process from lab to small pilot plant with respect to the industrial needs

7. Transfer the concept to at least one real demonstrator which will be tested for high corrosion and wear resistance

8. Evaluate the industrial impact of EQUINOX-concept with respect to economic as well as technical aspects.

equinox-project.eu


Specific objectives Lab

orato

ry scale . . . an

d b

eyon

d

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equinox-project.eu


Main impact

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equinox-project.eu


Main impact

M A I N I M P A C T EQUINOX would allow to save at least 18.000 Tons of CRM per year by substituting stainless steel

through CRM free Fe-Al based intermetallics (even without considering stainless steel flat products)

First conclusion: Substitution potential of stainless steel may be found in the market sector of “long product” which represents a volume of 6.6 Mio t p.a.

Flat products: attributing for 29.4 Mio t p.a. (82 % of the market) Long products: attributing for 6.6 Mio t p.a. (18 % of the market)

Second conclusion: the economic impact of EQUINOX would be equivalent to a substitution of 290 Mio € p.a. of semi-finished stainless steel products.

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equinox-project.eu


State of the Art (Steel Industry)

Step 1 Step 2

Step 3

Step 4

• A lot of energy is wasted • Major sources for CO2 emissions

• 43% is scrap material

• High transportation costs

• High transportation costs

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equinox-project.eu


State of the Art (Intermetallics)

The major problem with many intermetallics is their low ductility at ambient temperatures.

Before intermetallics can substitute stainless steel as structural materials in high volume markets, they have to be modified to improve their ductility,

without scarifying their strength and inherent corrosion and wear resistance.

Production technologies must be developed to translate these unique properties into technical products of complex 3D-geometry.

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equinox-project.eu


The research strategy focuses on the structural factors at the submicron level

A new concept beyond sheer material composition

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equinox-project.eu


Methodology

1. Fe porous preform 2. Al infiltration

3. Simulation

MIM SLM KE

Pressureless Pressure assisted

4. Subsequent heat treatment

5. Corrosion and mechanical testing

Microscopic Macroscopic

Phase tailoring Particle size tailoring

Optimization loop

6. Industrial demonstrator building

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equinox-project.eu


Work Package structure

WP1Porous

preforms

WP2Infiltration by liquid

Al

WP3Modelling

(Thermodynamics, kinetics)

WP4Microstructure, Heat treatment

WP5Corrosion,

Mechanical testing

WP6Demonstrator

WP7: Safe by Design - LCA WP8: Dissemination WP9: Management

WP2

WP1

Modify Al-melt tocontrol kinetics ?

Modify particlesurfacetocontrol wetting and kinetics ?

WP4

WP5

1.

2.

WP6 WP7

WP3

Op

tim

ized

Fe-

Al-b

ased

pa

rt

Te

sti

ng

De

mo

nst

rato

rs

Complex 3D-shaped part, from iron oxide

Porous preformbased on ultrafine

Fe particles

Porous preform, chemically tailored at

the grain surface

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equinox-project.eu


Milestones timeline

Milestone No

Milestone name Related

WP(s)

Estimated date

Means of verification

M1Feasibility of pressureless

infiltration2 M6

Definition of the method and the range of preform to

which is applicable

M2 Pressure-assisted infiltration 2 M33Optimal parameters for

pressure-assisted infiltration

M3 Model of Microsimulation 3 M6The model for microstructure

simulation is working

M4 Post heat treatment 4 M30Recommendation for the optimal

heat treatment processM5 First prototypes ready 6 M24 Produced piecesM6 Prototype approval 6 M32 Industrial testing results

M7 Industrial development 6 M36Road map and industrial scaling

reports

Feasibility study of one of the

methods for Al infiltration

Verification of the simulation

model reliability

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Thank you for your attention


National Technical University of Athens

research unit of advanced, composite, nanomaterials ...€¦ · research unit of advanced,...

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