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SEVENTH FRAMEWORK PROGRAMME THEME 4 – NMP: Nanosciences, Nanotechnologies, Materials and New Production Technologies Grant agreement no.: 228869 MICRO- AND NANOCRYSTALLINE CERAMIC - METAL FUNCTIONALLY GRADED MATERIALS FOR TRANSPORT APPLICATIONS Katarzyna Pietrzak 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’s to be: DEVELOPED CHARACTERISED MODELLED FGM I: Al2O3-Cu Al2O3-CuAg3Zr0.5 FGM II: Al2O3-NiAl Al2O3-Ni3Al APPLLICATIONS Thrusters Valves Brake disk APPLICATION Aerospace Thrusters FGM I Al2O3-Cu, Al2O3CuAg3Zr0.5 Automotive Al2O3-NiAl, Al2O3-Ni3Al 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 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) 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% FGM II Automotive SPECIFIC OBJECTIVE Workpackages WP 1: Material requirements and preparation of starting materials T1-1 Definition of target applications, demonstrators and material requirements T1-2 Preparation starting materials WP 2: Processing of FGMs T2-1 Powder metallurgy T2-2 Metal infiltration T2-3 Spraying T2-4 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 Modelling T4-1 Modelling of FGM design T4-2 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 components T5-3 Testing/evaluation of breaking discs components T5-4 Life cycle analysis WP 6: Management WP 7: Dissemination and networking 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), Germany Politecnico di Torino (POLITO), Italy Universita Politecnica delle Marche (UNIVPM), Italy MATRANS Consortium (16 partners) • Processing ITME Warsaw (PL) IFAM Dresden (D) TU Darmstadt (D) IMSAS Bratislava (SK) NTUA Athens (GR) POLITO, Torino (IT) WTU, Wroclaw (PL) • Characterisation IMIM Cracow (PL) UNIVPM Ancona (IT) NTUA Athens (GR) IFAM Dresden (D) • Modelling IPPT Warsaw (PL) UWC Cardiff (UK) TU Darmstadt (D) TU Kaiserslautern • Industry/SME CRF 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 and preliminary results Metal infiltration Powder metallurgy Poluethylene foam Ceramic preform Previous experience in FGM’s and preliminary results 25%Al2O3-75%Me 75%Al2O3-25%Me 50%Al2O3-50%Me Previous experience in FGM’s and preliminary results Al2O3 Me Al Steel THANK YOU FOR ATTENTION