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Professor Priit Kulu PhD student Liina Lind

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Outline 1. Introduction advanced materials in different areas trends & priorities 2. Advanced Materials metals, ceramics, composites & hybrids, carbon-family 3. Advanced materials technologies powder technology, casting, forming, machining 2High-Tech Materials & Technologies

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1. Introduction advanced materials in different areas trends & priorities 2. Advanced Materials metals, ceramics, composites & hybrids, carbon-family 3. Advanced materials technologies powder technology, casting, forming, machining 3High-Tech Materials & Technologies

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

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Definition State-of-art materials and coatings Technology based on recent achievements in physics, chemistry and biology Characterized by knowledge-intensity and process complexity Involving first of all manufacturing of coatings and novel ceramic & composite materials. High-Tech Materials & Technologies5

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Metals & Alloys Ceramics Polymers Composites High-Tech Materials & Technologies Metals Ceramics Glass Composites Polymers Cermets Glass-ceramics MCM MCMMetal composite materials CCMCeramic composite material PCMPolymeric composite material GCCMGlass-ceramic composite material FRGFiber-reinforced glass CCM PCM GCCM FRG 6 Main material groups

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Materials 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 & Technologies ACORD report from 2001 and BMW 7-series 2002-2008 Weight % of metals is decreasing, growing importance of polymers BMW 7-series 2002-2008 Metals 48+24=72% Polymers ~15%

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Trends in aviation High-Tech Materials & Technologies8

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

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Materials in medical applications Numerous biocompatible materials have found a place in medical applications Hip joints Dental implants Heart valves etc. High-Tech Materials & Technologies10 Ceramic Biocompatible coating (Ti-alloy)

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Materials in building and mechanical engineering 11High-Tech Materials & Technologies

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

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Materials 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 materials 13High-Tech Materials & Technologies

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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 14High-Tech Materials & Technologies

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

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Priorities of R&D (1) 1. Weight reduction 2. Low cost 3. High-temperature applications 4. Biocompatibility (for implants) 5. Multifunctionality and intelligence 16High-Tech Materials & Technologies

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Priorities of R&D (2) 6. Bioinspired materials learning from nature Field known as: biomimetics, bionics, biomimicry Velcro inspired from burdock Shark-skin inspired Speedo fastskins Materials with lotus-leaf effect 17High-Tech Materials & Technologies

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Priorities of R&D (3) 7. 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 & Technologies

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Priorities (4) 8. 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 MONTHS Scheme of the self-assembly of the Tobacco Mosaic Virus 19High-Tech Materials & Technologies

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1. Introduction advanced materials in different areas trends & priorities 2. Advanced Materials metals, ceramics, composites & hybrids, carbon-family 3. Advanced materials technologies powder technology, casting, forming, machining 20High-Tech Materials & Technologies

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Advanced metallic materials Metallic materials with superior properties Superconductive NbTi, Nb 3 Sn, Nb 3 Ge Structural alloys Neodymium rare-earth magnets (alloys of Nd, Fe and B) are strongest known permanent magnets. Sm-Co magnets Mg- and Al-alloys with superior properties, Al-metaglass, foams Ti-alloys with thermomechanical properties, superalloys, maraging steels, intermetallides, high-density alloys, shape-memory alloys Biocompatible Ti-alloys Amorphous alloys with chemical and thermal properties, Ni- and Fe aluminates 21High-Tech Materials & Technologies

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Advanced ceramic materials Oxide ceramics alumina, zirconia (Al 2 O 3 ) Non-oxide ceramics carbides, borides, nitrides, silicides (Si 3 N 4, SiC, B 4 C) 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 Composites particulate reinforced, combinations of oxides and non-oxides 22High-Tech Materials & Technologies

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Advanced ceramic materials Special oxide ceramics Electroceramics Non-oxide structural/tool ceramics Magnetic ceramics Mechanical and thermal properties Chemical and thermal properties Biocompatible ceramics Radiation resistance 23High-Tech Materials & Technologies Optical ceramics

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Ceramics for tools and parts Oxides: SiO 2, AlO 3, ZrO 2, MgO-based mullite (3Al 2 O 3 *2SiO 2 ) Carbides: WC, Cr 3 C 2, TiC, SiC, SiC, TiC SHS process (e.g. Si&C or Ti&C compounds) Nitrides: Si 3 N-based, AlN Composites: Ti(C,N), SiAl(OH) (sialon)-based 24High-Tech Materials & Technologies

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Toughness-hardness of ceramics , kg/m 3 HV *, GPa K 1C, MPa*m 0,5 WC15800246 Si 3 N 4 (hot-pressed) 3200165 Si 3 N 4 (reactive sintered) 3200822 SiO 2 (quartz) 270060,7 25High-Tech Materials & Technologies Property Type of ceramic

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Strength toughness of ceramics High-Tech Materials & Technologies26

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Metallic-ceramic tool and structural materials Carbide-steels and -alloys Ferro-TiC Steel (50 - 70)% -TiC Double reinforced MMC (Cr-steel + 20%VC) + 20%WC Self-fluxing alloys NiCrSiB + 50% (WC-Co) TiC-NiMo (50 - 60)% (NiMo)(2:1) 920 1620 HV10 Cr 3 C 2 -NiCr (50 - 60)% NiCr 27High-Tech Materials & Technologies

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Metallic-ceramic tool materials Some examples of carbide cermets WC-Co (6 - 30)% Co (hardmetals)890 - 1430 HV10 Cr 3 C 2 -Ni (10 - 30)% Ni880 - 1360 HV10 TiC-Ni-Mo (30 - 40)% NiMo(2:1)920 - 1260 HV10 TiC-steel (30 - 40)% austenitic/martensitic steel, 1050 - 1350 HV30 28High-Tech Materials & Technologies

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

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

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

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Typical structures of coatings Atomic layerDuplexMultilayer MonoCompositeGradient 32High-Tech Materials & Technologies

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Coating thickness and process temperatures of selected coating technologies High-Tech Materials & Technologies33 [Reference]

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

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

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Processing methods for selected materials Material systemForm of materialProcessing method Metal-ceramicBulk Casting, spraying, sintering, SHS Metal-polymerCoating Thermal spraying, PVD, CVD Ceramic-polymerFibre Deposition, grinding, spraying Metal-ceramic- polymer Powder High-Tech Materials & Technologies36

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1. Introduction advanced materials in different areas trends & priorities 2. Advanced Materials metals, ceramics, composites, carbon-family, hybrids, intelligent materials 3. Advanced materials technologies powder technology, casting, forming, machining 37High-Tech Materials & Technologies

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Material technologies Production of materials, Processing of materials, Manufacturing of products

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

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

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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) m Technologies powderforging (PF), e.g connecting rods Materials - 7,75 g/cm 3 gears PM details replace mechanically processed and moulded details PM Al- and Ti-alloys replace casting and forging 41High-Tech Materials & Technologies

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PM/HIP Powder 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 1. Inert gas atomizing to produce powder 3. The capsules are subjected to high isostatic pressure and high temperature to obtain full density 2. Sheet metal capsules are filled with the powder 42High-Tech Materials & Technologies

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

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Processing of hybrid materials High-Tech Materials & Technologies44 * SD Spray Deposition; HIP High Isostatic Pressing; SHS Selfpropagated High-temperature Synthesis; SPS Spray Plasma Sintering

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Comparison of processing technologies of hybrid materials CastingSDHIPSHSSPS Particle size, m Large500-1200

Sheet forming Sheet forming in superplastic state (SPF-process) (> T recrystallication, possibility to achieve large deformation values with one process, 1000 - 3000%) High-energy rate-forming (HERF-process) also known as high- velocity forming (HVF) (at high speed, no elastic after-effect) 53High-Tech Materials & Technologies

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Machining technology Integration of various cutting technologies into machining centres. 54High-Tech Materials & Technologies

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High precision tools for microcutting, laserforming and welding High-Tech Materials & Technologies55 3D-model of mold insertLaser welding nozzle Sliced 3D-modelLaser welded part from stellite

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Comparison of high- and ultra-precision cutting technologies DetailHigh-precisionUltrahigh-precision Accuracy < 1 m Submicron Roughness, Ra~ 10 nm~ 1 nm Processing2D and 3D2D Production scaleLong-runShort-run, 1-5 pc Materials No limitations, primarily steels Non-ferrous metals, crystalline materials, semiconductors 56High-Tech Materials & Technologies

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Intelligent tools Measuring process temperatures during processing High-precision cutting e.g. intelligent drilling /milling with programmable radial axis surface processing with a computer numerical control (CNC) tool high-precision drilling (accuracy 1 m) with punctual feed- rate, high L/d ratio High-Tech Materials & Technologies57

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Hard coatings in tooling traditional (Ti, Al)N HV 25 38GPa, hardness in elevated temperatures, heat-resitance, thermal conductivity multilayered alloyed nanostructured Nanostructured coatings High-Tech Materials & Technologies58

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Rapid prototyping (RP) CAD product (without machining) RP uses virtual designs from CAD or animation modeling software and transformes into thin, virtual, horizontal cross- sections and glues them together layer by layer to form a prototype. High-Tech Materials & Technologies59

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Technologies of RP and base materials Prototyping technologyBase materials Selective laser sintering Thermoplastics, metal powders Fused deposition modeling Themoplastics, eutectic metals StereolithographyPhotopolymer Laminated object manufacturingPaper Electron beam meltingTitanium alloys 3D printingVarious materials High-Tech Materials & Technologies60

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Rapid tooling (RT) Enables producing casting moulds for complex-shaped parts (lower cost, faster manufacturing) Producing of moulds by 3D printing using polymer or metallic powders. High-speed production of Al- and non-ferrous castings with low price

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Rapid manufacturing (RM) Enables production of end-products i.e. finished parts (sheet forming) it will never replace the mass production technologies (injection and die casting, sheet stamping); used mostly for production of parts with unique design (average 2 pcs; total in 2001 1,72 million parts).

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Additive Manufacturing Source: I. Gibson, D. W. Rosen, B. Stucker, Additive Manufacturing Technologies, Rapid Prototyping to Direct Digital Manufacturing. Springer, 2010.

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Example: housings for electronic devices

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Example: Architectural models

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Specific processing / manufacturing technologies Electroerosion process Electrochemical surface treatments Ultrasonic process Concentrated energy flow processes electron beam laser plasma Water jet (abrasive) 66High-Tech Materials & Technologies

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Water & laser cutting 67High-Tech Materials & Technologies

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TUT materials engineering web-site: www.ttu.ee/mtiwww.ttu.ee/mti mti@ttu.ee