Kõrgtehnoloogiamaterjalid High-Tech Materials & Technologies

1. KõrgtehnoloogiamaterjalidHigh-Tech Materials & Technologies Professor Priit Kulu PhD student Liina Lind

2. Outline • Introduction • advanced materials in different areas • trends & priorities • Advanced Materials • metals, • ceramics, • composites&hybrids, • carbon-family • Advanced materials technologies • powder technology, • casting, • forming, • machining High-Tech Materials & Technologies

3. Introduction • advanced materials in different areas • trends & priorities • Advanced Materials • metals, • ceramics, • composites & hybrids, • carbon-family • Advanced materials technologies • powder technology, • casting, • forming, • machining High-Tech Materials & Technologies

4. High-Tech (Advanced) Materials High-Tech Materials & Technologies

5. Definition • State-of-artmaterials and coatings • Technologybased on recentachievementsinphysics, chemistry and biology • Characterizedbyknowledge-intensity and processcomplexity • Involvingfirstof all manufacturingofcoatings and novelceramic & compositematerials. High-Tech Materials & Technologies

6. Main material groups Metals • Metals & Alloys • Ceramics • Polymers • Composites Cermets Ceramics MCM CCM Glass-ceramics Composites GCCM PCM FRG Polymers Glass MCM Metal composite materials CCM Ceramic composite material PCM Polymeric composite material GCCM Glass-ceramic composite material FRG Fiber-reinforced glass High-Tech Materials & Technologies

7. Polymers ~10% Ferrous + non-ferrousmetals 68+8=76% Passenger car compostion in 2001[ACORD, Annual Report 2001] Materials in a passenger car ACORD report from 2001 and BMW 7-series 2002-2008  Weight % ofmetalsisdecreasing, growingimportanceofpolymers Polymers ~15% Metals48+24=72% High-Tech Materials & Technologies BMW 7-series 2002-2008

8. Trends in aviation High-Tech Materials & Technologies

9. Materials in aviation Materials used in 787 Dreamliner, Boeing [Boeing AERO magazine 2006 - boeing.com/commercial/aeromagazine/articles/qtr_4_06] High-Tech Materials & Technologies

10. Materials in medical applications • Numerous biocompatible materials have found a place in medical applications • Hip joints • Dental implants • Heart valves etc. Ceramic (Ti-alloy) Biocompatible coating High-Tech Materials & Technologies

11. Materials in buildingand mechanical engineering High-Tech Materials & Technologies

12. Historical ages of materials Cu (COPPER) BRONZE IRON STONE POLYMERS STONE, WOOD 1 CERAMICS (STONE) COPPER, IRON 2 POLYMERS 3 4 TAILORED MATERIALS (composite materials) High-Tech Materials & Technologies

13. Materials R&D directions (European Technology Platform) • metallic structuralmaterials & metal-matrix composites (MMC), • non-metallic structuralmaterials (ceramics) & ceramic-matrix composites (CMC), • polymers & polymer-matrix composites, • multimaterials (e.g. hybrids), • conductive and magnetic materials, • biomaterials, • packaging materials, • lifecycleplanningand reuse of materials High-Tech Materials & Technologies

14. 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 High-Tech Materials & Technologies

15. Main trends (2) • Sustainable development • Sustainable technologies GRAPHICAL EXAMPLE FROM Mitsubishi Electric Group Environmental Vision 2021 in other words: REDUCE REUSE RECYCLE High-Tech Materials & Technologies

16. Priorities of R&D (1) • Weight reduction • Low cost • High-temperature applications • Biocompatibility (for implants) • Multifunctionality and intelligence High-Tech Materials & Technologies

17. Priorities of R&D (2) • Bioinspired materials – learning from nature Field known as: biomimetics, bionics, biomimicry Materials with lotus-leaf effect Velcro inspired from burdock Shark-skin inspired Speedo fastskins High-Tech Materials & Technologies

18. Priorities 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 High-Tech Materials & Technologies

19. Priorities (4) • Down-sizing(e.g. Moore’s 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 High-Tech Materials & Technologies

20. Introduction • advanced materials in different areas • trends & priorities • Advanced Materials • metals, • ceramics, • composites & hybrids, • carbon-family • Advanced materials technologies • powder technology, • casting, • forming, • machining High-Tech Materials & Technologies

21. Metallic materials with superior properties Structuralalloys Mg- and Al-alloys with superior properties, Al-metaglass, foams Superconductive NbTi, Nb3Sn, Nb3Ge Ti-alloys with thermomechanical properties, superalloys, maragingsteels, intermetallides, high-density alloys, shape-memory alloys Neodymium rare-earth magnets (alloysofNd, Fe and B) are strongestknownpermanentmagnets. Sm-Comagnets Amorphousalloyswithchemical and thermalproperties, Ni- and Fe aluminates Biocompatible Ti-alloys Advanced metallic materials High-Tech Materials & Technologies

22. Advanced ceramic materials 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 Non-oxide ceramics carbides, borides, nitrides, silicides (Si3N4, SiC, B4C) Oxide ceramics alumina, zirconia (Al2O3) Composites particulate reinforced, combinations of oxides and non-oxides High-Tech Materials & Technologies

23. Specialoxideceramics Non-oxidestructural/toolceramics Electroceramics Mechanical and thermalproperties Chemical and thermalproperties Magneticceramics Radiation resistance Biocompatibleceramics Advanced ceramic materials Opticalceramics High-Tech Materials & Technologies

24. Ceramics for tools and parts • Oxides: 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, AlN • Composites: Ti(C,N), SiAl(OH) (sialon)-based High-Tech Materials & Technologies

25. Toughness-hardness of ceramics Property Type of ceramic High-Tech Materials & Technologies

26. Strength – toughnessofceramics High-Tech Materials & Technologies

27. Metallic-ceramictool and structural materials Carbide-steelsand -alloys • Ferro-TiC Steel (50 - 70)% -TiC • Double reinforcedMMC (Cr-steel+ 20%VC) + 20%WC • Self-fluxing alloys NiCrSiB +  50% (WC-Co) • TiC-NiMo – (50 - 60)% (NiMo)(2:1) 920 – 1620 HV10 • Cr3C2-NiCr – (50 - 60)% NiCr High-Tech Materials & Technologies

28. Metallic-ceramic tool materials Some examples of carbide cermets • WC-Co – (6 - 30)% Co (hardmetals) 890 - 1430 HV10 • Cr3C2-Ni – (10 - 30)% Ni 880 - 1360 HV10 • TiC-Ni-Mo – (30 - 40)% NiMo(2:1) 920 - 1260 HV10 • TiC-steel – (30 - 40)% austenitic/martensitic steel, 1050 - 1350 HV30 High-Tech Materials & Technologies

29. Hardness-toughness of materials 1.CERAMICS 2.WHITE CAST IRON 3.CERMETS 4.METAL MATRIX COMPOSITES (MMC) 5.TOOL STEELS 6.CARBON AND STAINLESS STEELS Hardness Toughness High-Tech Materials & Technologies

30. Special purpose Structural / tool Electrocomposites (PM, CM) Mechanical properties (PM, CM) Optical (PM) Thermomechanicalproperties (CM, CaM, MM) Biocompatible (CaM, PM, CM) Radiationresistance (CM, CaM) Advanced composites PM – polymer matrix MM – metal matrix CM – ceramic matrix CaM – carbon matrix High-Tech Materials & Technologies

31. Particle reinforced Short fibrereinforced Continuous fibre reinforced Sandwich-type Coated Typical structures of composites High-Tech Materials & Technologies

32. Typical structures of coatings Mono Composite Gradient Multilayer Atomic layer Duplex High-Tech Materials & Technologies

33. Coating thickness and process temperatures of selected coating technologies [Reference] High-Tech Materials & Technologies

34. Carbon based materials Carbon family graphite, diamond, fullerens, carbon nanofibers (CNF) & tubes (CNT), diamond-like-carbon (DLC) coatings 34

35. Working temperature of various structural materials Heat-resistant Not heat-resistant Mono-crystals TMT alloys Force-crystallized eutectic fast-hardened alloys Ti-composites Specific strength Superalloys Graphite Titanium Ceramics/graphite TiAl alloys Sintered alloys Al- alloy composites High-melting-point alloys Operating temperature (°C) High-Tech Materials & Technologies

36. Processingmethodsforselectedmaterials High-Tech Materials & Technologies

37. Introduction • advancedmaterialsindifferentareas • trends & priorities • AdvancedMaterials • metals, • ceramics, • composites, • carbon-family, • hybrids, • intelligent materials • Advancedmaterialstechnologies • powdertechnology, • casting, • forming, • machining High-Tech Materials & Technologies

38. Material technologies • Production of materials, • Processing of materials, • Manufacturing of products

39. Advanced materialstechnologies • Powder technologies • Casting • Forming • Machining • Rapid Prototyping • Joining technologies High-Tech Materials & Technologies

40. Powder technology in materials engineering High-Tech Materials & Technologies

41. Powder metallurgy (PM) Associated primarily with automotive industry →(e.g. in 2004 an average car in USA had 19,5 kg of PM detailsnew engines 12 kg of PM details) Powders – prealloyed powders, finedopants – Ni (1 – 2) m Technologies – powderforging (PF), e.g connectingrods Materials -   7,75 g/cm3 – gears • PM details  replace mechanically processed and moulded details • PM Al- and Ti-alloysreplacecasting and forging High-Tech Materials & Technologies

42. 1. Inert gas atomizingto produce powder 2. Sheet metal capsulesare filled with the powder 3. The capsules are subjected to highisostatic pressure and high temperatureto obtain full density PM/HIPPowder 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 High-Tech Materials & Technologies

43. SF /HIP Similar to PM/HIP, slab formation by spraying methods High-Tech Materials & Technologies

44. Processing of hybrid materials * SD – Spray Deposition; HIP – High Isostatic Pressing; SHS – Selfpropagated High-temperature Synthesis; SPS – Spray Plasma Sintering High-Tech Materials & Technologies

45. Comparison of processingtechnologiesofhybridmaterials * SD – Spray Deposition; HIP – High Isostatic Pressing; SHS – Selfpropagated High-temperature Synthesis; SPS – Spray Plasma Sintering High-Tech Materials & Technologies

46. Comparison of material groups produced with different methods High-Tech Materials & Technologies

47. Comparison of different technologies HVOF  porosity Al2O3-Ni WC-Co  dopants for increasing Al2O3-ZrO2 (mulliit??) toughness Al2O3-SiC  grain size  -fraction SD • % of hard phase  20...30 • fine structure • good strength High-Tech Materials & Technologies

48. Casting trends (USA 2002-2009) Main industry – car manufacturing (35%) pipelines, drainage (15%) mining/oil industry (6%) High-Tech Materials & Technologies

49. Types of casting • investmentcasting • castingwithgasifiedmodels • castingwithsolublemodels High-Tech Materials & Technologies

50. Castingusing RT producedmoulds Z Cast-process Producing of moulds by 3D printing using polymer or metallic powders. High-speed production of Al- and non-ferrous castings with low price High-Tech Materials & Technologies