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There are many activities worldwide to overcome these problems in industry and to develop components which are less susceptible to friction and wear. In a reciprocal manner friction affects also day-life products e. Nowadays many innovative techniques are applied to increase the working-life of a component. Some current solutions to compensate the problem of friction are the use of parts with hard coatings or self-lubricating surfaces. Drawbacks in manufacturing of these coatings are still present. The processing of solid lubricant coated parts involve complex and elaborate steps as well as highly expensive equipment and materials.
In order to increase the energetic efficiency of the products the route of Polymer Derived Ceramic PDC seems to be a promising technology regarding to the processing of tailored surfaces on metal parts. Due to the polymeric behavior of the precursor different shaping techniques dipping, spraying, spin-coating for applying a coating can be used. The unique structure of the polymers are particularly advantageous for a strong adhesion at the metal surfaces. In order to tailor the coating properties like increasing the hardness, influencing the tribological behavior or adjusting the mismatch in thermal expansion between coating and substrate the polymers can be loaded with additional filler materials, e.
The aim of this project is to develop PDC coatings on sintered, pre-sintered and non-sintered parts. The goal is to obtain a metal component with a wear resistant surface by using hard ceramic phases e. Si3N4 or SiC in combination with a dry self-lubricant feature represented by ceramics with a low coefficient of friction e. Thermal treatment of the coated samples in highly reactive environments should exert a positive influence on the coating properties.
The processing scientists work together interdisciplinary in order to combine various expertise in the field of metal processing and polymer derived ceramics to develop a new coating technology. Technical applications of nanomaterials have received special attention due to their desirable characteristics in strategical areas such as catalysis, pigments, health, food, treatment of surfaces, among others. In the engineering field, nanomaterials or nanoparticles have fundamental applications in the development of catalysts and sensors, where the specific process functionality and quality is only achieved in nanostructures with high surface area and small particle sizes below approximately 20 nm.
For applications of nanostructured materials, the particle formation and production step as well as the formulation of these particles in terms of surface layers and coatings need to be addressed properly to transfer nanostructured materials into industrial products. In this sense, the development of improved manufacturing processes employing nanoparticles is presented as a strategic theme for the scientific and technological development.
Nanoparticles with high purity and narrow particle size distributions can be produced efficiently and economically in pyrolysis reactors e. These reactors are the central core of the FSP process "Flame Spray Pyrolysis" and are obtained by the combustion processes of drops of a liquid fuel ethanol, iso-octane, aromatic hydrocarbons. These small drops contain a dissolved metal precursor produced by an axial spray in contact with an oxidant sonic jet, with consequent formation of the flaming spray.
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The main flame typically is stabilized by a pilot flame by burning a premixed gaseous hydrocarbon and the nanoparticles are nucleated in the frontal region of the flame after the evaporation and burning of the fuel and the precursor. In the region of the main flame occurs the entrance of external air which ensures the supply of oxidant oxygen required for complete fuel combustion and oxidation of the precursor and subsequent formation of nanoparticles.
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The FSP process is capable to produce nanoparticles and mixtures of metal oxide particles with sizes in the range varying from 1 to nm, which are based on low cost metallic precursor materials. The main objectives of the project may be summarized as: - Derivation of suitable process conditions for manufacturing of tailored nanostructured coatings. Future investigations of the project contain the development of new reactor concepts for simultaneous synthesis of metal oxide and carbon black nanoparticles with specific application in Li-ion-battery manufacturing.
Surface structures are used to extend technical components life. Surface structures, also called functional surfaces, provide additional space for cooling lubricant and favour the generation of pressure in the lubrication film at low sliding speeds.
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As a consequence, friction in technical components is decreased, resulting in reduced wear. The manufacturing of such structures is nowadays generally done applying lithography, etching, laser techniques and high-precision machining. In this collaborative project, conventional grinding using special grinding wheels with defined topographies will be applied to manufacture structured surfaces, which is only marginally researched so far.
Grinding will allow a much faster production of structured surfaces in several kinds of material to improve efficiency and sustainability of materials used in technical components. Besides the defined topographies of the tools, it is essential to know and control the kinematics of the process to be able to manufacture deterministic structures. This will be achieved by deriving analytical equations that specify the kinematics of the proposed grinding process.
In this collaborative project, two different kinds of special grinding wheels and kinematics will be developed and researched. The German research group will focus on grinding wheels with defined grain patterns for surface grinding, whereas the Brazilian research group will focus on special conditioning of the bond of grinding wheels applying a cylindrical plunge grinding process. By applying surface and cylindrical grinding, all geometries relevant for sliding components will be considered. Based on the analytical equations specifying the respective kinematics, each research group will develop a simulation tool.
The required grinding wheel patterns accordant to desired structures of the Brazilian Group will be simulated using a pattern generation and mapping software, previously developed at the Brazilian Institute and to be enhanced during the proposed project. The German Research group will develop a simulation tool that is able to identify and visualize needed grain patterns for desired surface structures and vice versa. The manufactured structured surfaces from both groups will be optically mapped and their tribological performance will be evaluated.
By comparing the possibilities and limitations of the respective approaches, a comprehensive knowledge of the capabilities of grinding structured surfaces will be achieved.
The unrestricted exchange of the research results will lead to results impossible to achieve in individual projects and will strengthen the relationship of this binational research group. In this project, multicomponent Cu-based shape memory alloys SMAs shall be processed by the relatively new technique of selective laser melting, which is expected to result in components with advanced mechanical properties.
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The alloy powder required for this manufacturing process is synthesised by spray forming. The goals of this project are to study the influence of two rapid solidification methods spray forming and SLM on the microstructure and the shape memory effect of two Cu-based SMAs, viz. The mechanical properties shall be analysed with focus on the interrelation between the microstructure e. Considering that high cooling rates can be reached by this method, the influence of rapid solidification on phase formation and grain size, mechanical properties and shape memory effect of Cu-based shape memory alloys will be studied.
Advanced Ceramics have been applied on many areas of engineering and related concerns of microgrinding are aspects of advanced manufacturing that have been growing together. Lenses, mirrors, mechanical parts, medical products, cutting tools, mechanical systems, electronics, armor, chemical, MEMS parts, and a wide variety of sensors are examples for commercial purposes. All these applications need to be manufactured with precise standards using micro grinding techniques. Most of these applications require a crack-free surface.
Usually, hard and brittle materials such as glass, silicon, zirconium oxide, aluminum oxide, PZT ceramics and germanium are commonly used for making these products. The advances on micro grinding of brittle materials have led to the discovery of a ductile regime in which material removal is performed by plastic deformation. Fracture mechanics predict that even brittle solids can be machined by the action of plastic flow, as it is the case for metal, leaving crack free surfaces when the removal process is performed at less than a critical depth of cut. For the processing of piezoelectric ceramics the state of the art shows that further fundamental studies have to be carried out in order to learn about the cutting behavior.
Within a first research period basic knowledge about the cutting behavior of PZT ceramic was gained. With this knowledge the basic machinability could be classified. Due to these investigations it is known which parameters and tools are suitable for machining. Additionally, the monitoring process during machining with microgrinding pins could be successfully implemented. However, these studies have been restricted to the production of grooves.
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Complex structures such as pillar arrays have not been made. Therefore, it is yet not identified what aspect ratios can be achieved in piezoelectric ceramics. Within this funding period the processing of piezoelectric ceramics will be further investigated, based on the results of the initial research project. In addition, the monitoring process during micromachining is limited. The forces that occur are very low. Moreover, the maximum revolutions of the spindle system have to be very high in order to achieve the re-quired cutting speeds.
This is often in the range of the natural frequency of the sensors, so that no proper measurements can be taken. Therefore, special sensors, with natural frequencies outside the excited fre-quencies, have to be used. Conventional positioning methods in macro-scale machining usually reach accu-racies that are not sufficient for micromachining. Therefore, it is necessary to develop process monitoring systems that increase the machining accuracy.
So far, the quality of the components is determined outside of the machine. However, it is not possible to clamp the components back in the same position in the ma-chine.
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Thus, a post-processing of the structures is not yet possible. In addition, micro machining is very time consuming. Early detection of tool failure would therefore lead to a possible reduction of post-processing time. A large proportion of studies that deal with the monitoring process in micromachining focus on geometrically defined cutting especially milling and drilling.
Periodic signals are analyzed whereas the change of the signal indicates tool wear. Regarding the monitoring process for micro-grinding only few studies exist. These deal with the use of grinding pins. The influence of tool diameter on the monitoring process has not yet been investigated.
In addition studies on the use of a monitoring process in micro-grinding with Dicingblades are lacking. As part of the research project this gap should be closed in order to identify process-tool failure. In the first research period a potential connection between the tool state and the force measurements was found to be verified in the period requested. The trend for product individualization results in a demand for small and more flexible production series. The improvement of production flexibility increases the control complexity of the manufacturing tasks, leading to big challenges for quality assurance systems.
The major challenge faced by a quality assurance system applied to small series production is to guarantee the needed quality level already at the first run first time right on time. This demands a constant adaption of the quality assurance system behavior according to the dynamic manufacturing conditions, which can be achieved by the improvement of cognitive and autonomy aspects of the manufacturing systems. The innovative concept of Cognitive Metrology focuses on increasing the manufacturing efficiency and quality within small series through the capacitation of flexible and adaptive production metrology.
X-Ray computed tomography CT is an emerging non-destructive technology for the dimensional measurement of precision plastic parts with complex geometry. With CT this geometry can be acquired holistically, i.