Krgtehnoloogiamaterjalid Advanced Engineering Materials and Technologies (High-Tech Materials & Technologies)

Krgtehnoloogiamaterjalid

High-Tech Materials & TechnologiesProfessor Priit KuluPhD student Liina Lind

OutlineIntroductionadvanced materials in different areastrends & prioritiesAdvanced Materials metals, ceramics, composites & hybrids,carbon-familyAdvanced materials technologiespowder technology, casting,forming,machining2High-Tech Materials & Technologies2Introductionadvanced materials in different areastrends & prioritiesAdvanced Materials metals, ceramics, composites & hybrids,carbon-familyAdvanced materials technologiespowder technology, casting,forming,machining3High-Tech Materials & Technologies3High-Tech (Advanced) Materials

4High-Tech Materials & TechnologiesDefinitionState-of-art materials and coatingsTechnology based on recent achievements in physics, chemistry and biologyCharacterized by knowledge-intensity and process complexity

Involving first of all manufacturing of coatings and novel ceramic & composite materials.High-Tech Materials & Technologies5Metals & Alloys

Ceramics

Polymers

CompositesHigh-Tech Materials & Technologies

Metals

Ceramics

Glass

CompositesPolymers

Cermets

Glass-ceramics

MCM

MCMMetal composite materialsCCMCeramic composite materialPCMPolymeric composite materialGCCMGlass-ceramic composite materialFRGFiber-reinforced glassCCMPCMGCCM

FRG6Main material groupsMaterials 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 & TechnologiesACORD report from 2001 and BMW 7-series 2002-2008

Weight % of metals is decreasing, growing importance of polymersBMW 7-series 2002-2008Metals 48+24=72%Polymers ~15%Trends in aviationHigh-Tech Materials & Technologies8

Materials in aviation

Materials used in 787 Dreamliner, Boeing[Boeing AERO magazine 2006 - boeing.com/commercial/aeromagazine/articles/qtr_4_06]9High-Tech Materials & TechnologiesMaterials in medical applicationsNumerous biocompatible materials have found a place in medical applicationsHip jointsDental implantsHeart valvesetc.

High-Tech Materials & Technologies10CeramicBiocompatible coating(Ti-alloy)Materials in building and mechanical engineering11High-Tech Materials & Technologies

Historical ages of materialsSTONECu (COPPER)BRONZEIRONPOLYMERSCERAMICS (STONE)STONE, WOODCOPPER, IRONPOLYMERSTAILORED MATERIALS (composite materials)123412High-Tech Materials & TechnologiesMaterials R&D directions (European Technology Platform)metallic structural materials & metal-matrix composites (MMC),non-metallic structural materials (ceramics) & ceramic-matrix composites (CMC), polymers & polymer-matrix composites,multimaterials (e.g. hybrids), conductive and magnetic materials, biomaterials, packaging materials, lifecycle planning and reuse of materials13High-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 materials14High-Tech Materials & Technologies

Main trends (2)Sustainable development

Sustainable technologies

GRAPHICAL EXAMPLE FROMMitsubishi Electric GroupEnvironmental Vision 2021 15High-Tech Materials & Technologiesin other words:REDUCEREUSERECYCLEPriorities of R&D (1)Weight reduction

Low cost

High-temperature applications

Biocompatibility (for implants)

Multifunctionality and intelligence

16High-Tech Materials & TechnologiesPriorities of R&D (2)Bioinspired materials learning from nature

Field known as: biomimetics, bionics, biomimicry

Velcro inspired from burdock

Shark-skin inspired Speedo fastskins

Materials with lotus-leaf effect17High-Tech Materials & TechnologiesPriorities of R&D (3)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 & TechnologiesPriorities (4) 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 MONTHSScheme of the self-assembly of the Tobacco Mosaic Virus19High-Tech Materials & TechnologiesIntroductionadvanced materials in different areastrends & prioritiesAdvanced Materials metals, ceramics, composites & hybrids, carbon-familyAdvanced materials technologiespowder technology, casting,forming,machining20High-Tech Materials & Technologies20Advanced metallic materialsMetallic materials with superior propertiesSuperconductive NbTi, Nb3Sn, Nb3GeStructural alloysNeodymium rare-earth magnets (alloys of Nd, Fe and B) are strongest known permanent magnets. Sm-Co magnetsMg- and Al-alloys with superior properties, Al-metaglass, foamsTi-alloys with thermomechanical properties, superalloys, maraging steels, intermetallides, high-density alloys, shape-memory alloysBiocompatible Ti-alloysAmorphous alloys with chemical and thermal properties, Ni- and Fe aluminates 21High-Tech Materials & TechnologiesAdvanced ceramic materialsOxide ceramics alumina, zirconia (Al2O3)Non-oxide ceramics carbides, borides, nitrides, silicides (Si3N4, SiC, B4C)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 costComposites particulate reinforced, combinations of oxides and non-oxides22High-Tech Materials & TechnologiesAdvanced ceramic materialsSpecial oxide ceramicsElectroceramicsNon-oxide structural/tool ceramicsMagnetic ceramicsMechanical and thermal propertiesChemical and thermal propertiesBiocompatible ceramicsRadiation resistance23High-Tech Materials & TechnologiesOptical ceramicsCeramics for tools and partsOxides: SiO2, AlO3, ZrO2, MgO-basedmullite (3Al2O3*2SiO2)Carbides: WC, Cr3C2, TiC, SiC, SiC, TiC SHS process (e.g. Si&C or Ti&C compounds)Nitrides: Si3N-based, AlNComposites: Ti(C,N), SiAl(OH) (sialon)-based24High-Tech Materials & TechnologiesToughness-hardness of ceramics, kg/m3HV*, GPaK1C, MPa*m0,5WC15800246Si3N4 (hot-pressed)3200165Si3N4 (reactive sintered)3200822SiO2 (quartz)270060,725High-Tech Materials & TechnologiesPropertyType of ceramicStrength toughness of ceramics

High-Tech Materials & Technologies26Metallic-ceramic tool and structural materialsCarbide-steels and -alloysFerro-TiC Steel (50 - 70)% -TiCDouble reinforced MMC(Cr-steel + 20%VC) + 20%WCSelf-fluxing alloysNiCrSiB + 50% (WC-Co)

TiC-NiMo (50 - 60)% (NiMo)(2:1) 920 1620 HV10Cr3C2-NiCr (50 - 60)% NiCr

27High-Tech Materials & TechnologiesMetallic-ceramic tool materialsSome examples of carbide cermets

WC-Co (6 - 30)% Co (hardmetals)890 - 1430 HV10Cr3C2-Ni (10 - 30)% Ni880 - 1360 HV10TiC-Ni-Mo (30 - 40)% NiMo(2:1)920 - 1260 HV10TiC-steel (30 - 40)% austenitic/martensitic steel, 1050 - 1350 HV3028High-Tech Materials & TechnologiesHardness-toughness of materials

HardnessToughness1. CERAMICS2. WHITE CAST IRON3. CERMETS4. METAL MATRIX COMPOSITES (MMC)5. TOOL STEELS6. CARBON AND STAINLESS STEELS29High-Tech Materials & TechnologiesAdvanced compositesSpecial purposeElectrocomposites (PM, CM)Structural / toolOptical (PM)Mechanical properties (PM, CM)Thermomechanical properties (CM, CaM, MM)Biocompatible (CaM, PM, CM)Radiation resistance (CM, CaM)30High-Tech Materials & TechnologiesPM polymer matrixMM metal matrixCM ceramic matrixCaM carbon matrixTypical structures of composites

Particle reinforcedShort fibre reinforcedContinuous fibre reinforcedSandwich-typeCoated31High-Tech Materials & TechnologiesTypical structures of coatings

Atomic layerDuplexMultilayerMonoCompositeGradient32High-Tech Materials & TechnologiesCoating thickness and process temperatures of selected coating technologies

High-Tech Materials & Technologies33[Reference]34Carbon based materialsCarbon familygraphite,diamond,fullerens,carbon nanofibers (CNF) & tubes (CNT),diamond-like-carbon (DLC) coatings

Working temperature of various structural materials

35High-Tech Materials & TechnologiesSpecific strengthOperating temperature (C)Ti-compositesTitaniumTiAl alloysAl- alloy compositesSuperalloysGraphiteHeat-resistantTMT alloysMono-crystalsForce-crystallized eutectic fast-hardened alloysSintered alloysCeramics/graphiteHigh-melting-point alloysNot heat-resistantProcessing methods for selected materialsMaterial systemForm of materialProcessing methodMetal-ceramicBulkCasting, spraying, sintering, SHSMetal-polymerCoatingThermal spraying, PVD, CVDCeramic-polymerFibreDeposition, grinding, sprayingMetal-ceramic-polymerPowder High-Tech Materials & Technologies36Introductionadvanced materials in different areastrends & prioritiesAdvanced Materials metals, ceramics, composites, carbon-family,hybrids,intelligent materialsAdvanced materials technologiespowder technology, casting,forming,machining37High-Tech Materials & Technologies37Material technologiesProduction of materials,Processing of materials,Manufacturing of productsAdvanced materials technologiesPowder technologiesCastingFormingMachiningRapid PrototypingJoining technologies39High-Tech Materials & TechnologiesPowder technology in materials engineering40High-Tech Materials & Technologies

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) mTechnologies powderforging (PF), e.g connecting rodsMaterials - 7,75 g/cm3 gearsPM details replace mechanically processed and moulded detailsPM Al- and Ti-alloys replace casting and forging

41High-Tech Materials & TechnologiesPM/HIPPowder Metallurgy / High Isostatic PressingAdvantages:Very fine microstructure and isotopic properties enables UT, insucseptible to hydrogen brittleness (HISC)othersclose to product-shape,flexible construction,good mechanical properties, small series

1.Inert gas atomizingto produce powder3.The capsules are subjected to highisostatic pressure and high temperatureto obtain full density2.Sheet metal capsulesare filled with the powder42High-Tech Materials & TechnologiesSF /HIP

Similar to PM/HIP, slab formation by spraying methods43High-Tech Materials & TechnologiesProcessing of hybrid materialsHigh-Tech Materials & Technologies44* SD Spray Deposition; HIP High Isostatic Pressing; SHS SelfpropagatedHigh-temperature Synthesis; SPS Spray Plasma Sintering4444Comparison of processing technologies of hybrid materialsCastingSDHIPSHSSPSParticle size, mmLarge500-1200