WG1. Materials for Transport


Thematic scope

The working "Materials for Transport" focused on materials developments for transport application. The main focus is on ferrous and non-ferrous materials (e.g. aluminum, titanium) and "other" materials like polymers or composites.

Structure of the WG1

The structure of the WG is still under discussion. At the moment the coordinators have proposed thematic sub-groups based on transport sectors (i.e. aerospace, automotive etc.) but the final strcuture will be adapted to the thematic scope of the project proposals that will be set up in 2013.

Summary of activities in 2012 and action plan for 2013

In 2012 KMM-VIN partners were asked for their interest and special competencies in this field. 43 partners expressed their interest and 17 R&D proposals were submitted. For 2013 the working group will mainly focus on a more detailed definition of sub-groups and to start with joint R&D work based on the already existing proposals.

Meetings planned

WG1 annual meeting will be held on 19th Feb. 2014 in Brussels.

KMM-VIN 3rd Industrial Workshop on „Advanced Manufacturing Technologies for Transport Applications” is planned at Fraunhofer-IFAM, Dresden, in November 2014.

Summary of project proposals a

 

Title

Proposer

Interested parties

1

Material development and modelling of metal-matrix composites with enhanced mechanical properties

IPPT

AGH/WRUT/IMIM/CIDETEC/UNIVPM/ITME

2

Multi-scale diagnostics of microstructure

IMIM

TECNALIA/IMIM/CIDETEC/UNIVPM

3

High temperature alloys for joining dissimilar materials in automotive industry

IMIM

POLITO/IMIM/UNIVPM

4

Joining technologies for dissimilar materials

TUC

WRUT/POLITO/IMIM/CIDETEC/UNIVPM

5

Development of high performance aluminium

IFAM-DD

CIDETEC/IMIM/UNIVPM

6

Ultra-light hybrid materials metal-polymer for transport applications

WRUT

IMIM/UNIVPM

7

Electron beam welding of thick walled dissimilar materials

TUG

IMIM/UNIVPM

8

Friction stir welding of dissimilar materials

TUG

IMIM/UNIVPM

9

Research and development of steels compositions with nanostructures produced under pressure

IMBAS

AGH/IMIM/UNIVPM

10

Self-healing elastomeric materials for automotive applications

CIDETEC

AGH/IMIM/UNIVPM

11

Thermoplastic leather composite materials for automotive applications

CIDETEC

TUWIEN/AGH/IMIM

12

Advanced coatings for high performance magnesium alloy cars parts

CIDETEC

IMIM

13

Innovative coatings and surface treatments for low friction aeronautic gears

CIDETEC

TECNALIA/IMIM/CIDETEC/UNIVPM

14

Coating of C-C composites for ultrasonic vehicles

UH

POLITO/IMIM/UNIVPM

15

Electromagnetic processing of automotive body materials, materials for marine applications, etc

UH

IMIM/UNIVPM

16

Catalytic oxidation of carbon-carbon aircraft brakes

UH

IMIM/UNIVPM

17

Development of magnesium based composite materials

TECNALIA

WRUT/IMIM/UNIVPM


Proposal 1   (top ►)

Project title

Material development and modelling of metal-matrix composites with enhanced mechanical properties.

Sub-Groups

SG 1:  Materials for Aerospace
SG 2:  Materials for Automotive

Short Summary

The improvement of energy efficiency in transport (automotive and air) requires new lightweight materials with enhanced mechanical properties such as e.g. MMC’s consisting of NiAl phase reinforced by Al2O3 fibers or particles. The development of the technology of these materials by pressure sintering, analysis of the influence of shape, ratio, type of the reinforcement on the properties and morphology of obtained materials will be the focus of the proposed project.

Contact:

Prof. Michal Basista, Prof. K. Pietrzak, Dr. Witold Węglewski 
Institute of Fundamental Technological Research of the Polish Academy of Sciences
Research Group on Advanced Composite Materials
Pawinskiego 5B, 01-406 Warszawa, Poland
+4822 828 5374, +48 668 160 300


Proposal 2   (top ►)

Project Title

Multi-scale diagnostics of microstructure

Sub-Groups

SG 1:  Materials for Aerospace
SG 2:  Materials for Automotive

Short Summary

The proposal is a general offer for several material characterization techniques which can be of interest of both sub-groups.
The following techniques are offered:

- Microstructure, local phase and chemical analysis in thin foils and solid samples
- Stress and texture analysis by X-ray diffraction technique
- Materials homogeneity by acoustic techniques

Contact:

Prof. Jan Bonarski,  Prof.  Jerzy Morgiel, Prof. Marek Faryna
Institute of Metallurgy and Materials Science, Polish
Academy of Sciences25 Reymonta Str.
30-059 Kraków
+48 12 295.2871
j.bonarski@imim.pl


Proposal 3    (top ►)

Project Title

High temperature alloys for joining dissimilar materials in automotive industry

Sub-Group

SG 2:  Materials for Automotive

Short Summary

Legislation requires that new solders for joining (brazing) of dissimilar materials (namely Cu and Al or their alloys) be developed. These solders could be applied in engine accessories or cooler in a car. The aim of this project is to gather the data regarding properties and performance of alloys that could be applied in high temperature conditions. Proposed alloys are Zn-Al (eutectic and near-eutectic alloys) alloyed with Si (up to 5%), Li, K, Na (about 0.5%). The great advantage of Zn-Al alloys is that they are already proven to be useful for joining Cu and Al. The proposed additions are expected to substantially improve properties of these alloys i.e. wetting (by reducing the surface tension – the proposed additions are surface active), oxidation resistance, etc.

Contact:

Dr. Tomasz Gancarz, Dr. Przemyslaw Fima
Institute of Metallurgy and Materials Science Polish Academy of Sciences
Reymonta St. 25, PL30-059 Krakow, Poland
+48 12 295 2824
t.gancarz@imim.pl, p.fima@imim.pl


Proposal 4     (top ►)

Project Title

Dissimilar joints between metal- and (fibre-reinforced) plastics

Sub-Group

SG 2:  Materials for Automotive

Short Summary

The improvement of energy efficiency in transport requires new lightweight constructions consisting of metals as well as plastics. To realise load-bearing constructions, it is necessary to join these different materials and also achieving high strength of the joints. This proposal is focused on the joining of carbon-fibre-reinforced thermoplastics PA6 in combination with steel without the use of adhesives. This can be realised by a combination of defined heat and pressure on the joining zone. One result will be a categorisation and a comparison between direct and indirect heating methods.

Contact:

Prof. Peter Mayr, Dr.-Ing. Mario Kusch
Chemnitz University of Technology
Department of Mechanical Engineering
Institute of joining and assembly
Chair of Welding Engineering
+49 (0)371/53123720; schweisstech@mb.tu-chemnitz.de


Proposal 5   (top ►)

Project Title

High Performance Aluminium Alloys prepared by SPS

Sub-Group

SG 1: Materials for Aerospace
SG 2:  Materials for Automotive

Short Summary

The objective of the project is to evaluate a cost-efficient way to produce high performance aluminium alloys with excellent mechanical properties at room and elevated temperatures. Therefore rapidly solidified powders or melt-spun flakes will be consolidated by SPS. The pre-compacts have to be formed into the final shape by extrusion or forging.

Contact:

Dr.-Ing. Thomas Weissgaerber, Dr.-Ing. Thomas Schubert
Fraunhofer Institute for Manufacturing and Advanced Materials, Branch Lab Powder Metallurgy and Composite Materials Dresden, FhG-IFAM DD, Winterbergstrasse 28, 01277 Dresden, Germany
+49-351-2537 305
Thomas.Weissgaerber@ifam-dd.fraunhofer.de


Proposal 6   (top ►)

Project Title

Ultralight hybrid materials metal-polymer for transport applications

Sub-Group

SG 1: Materials for Aerospace
SG 2:  Materials for Automotive

Short Summary

The objective of the project is to design and manufacture high strength ultralight hybrid elements composed of high strength light metals and high strength polymers.Chosen ultralight hybrid elements of metal-polymer type manufactured by injection molding of liquid polymer into the spatial structure of Al sheets. The example of deliverable can be taken from the car or aircraft industry

Contact:

Prof. Jacek W. Kaczmar
Dr. Krzysztof Naplocha
Politechnika Wrocławska - Wrocław University of Technology WRUT
50-370 Wrocław, W. Wyspiańskiego 27, Poland
+48-71-3202758 ande mobile: +48 - 603 123846
jacek.kaczmar@pwr.wroc.pl


Proposal 7   (top ►)

Project Title

Electron Beam Welding (EBW) of thick walled dissimilar materials

Sub-Group

SG 1: Materials for Aerospace
SG 2:  Materials for Automotive

Short Summary

The goal of the project is to join different thick walled materials by means of EBW. Parameters for optimized welding have to be chosen and characterization of the joints has to be performed.

Contact:

Assoc. Prof. Dr. N. Enzinger
Institute for Materials Science and Welding, Graz University of Technology (IWS)
++43 (0)664 71732078
Norbert.Enzinger@TUGraz.at


Proposal 8   (top ►)

Project Title

Friction Stir Welding (FSW) of dissimilar materials

Sub-Group

SG 1: Materials for Aerospace
SG 2:  Materials for Automotive

Short Summary

The goal of the project is to join different sheet materials by means of FSW. Parameters for optimized welding have to be chosen and the characterization of the joints has to be performed.

Contact:

Assoc. Prof. Dr. N. Enzinger
Institute for Materials Science and Welding, Graz University of Technology (IWS)
++43 (0)664 71732078
Norbert.Enzinger@TUGraz.at


Proposal 9   (top ►)

Project Title

Research and development of steel compositions with nanostructures produced under pressure

Sub-Group

SG 3: Materials for Railway

Short Summary

The goal of the project is to develop counter gravity casting processes for the production of advanced steels to be applied in the production of elements for the future railroad transport system. New steel compositions will be developed with the equipment available at IMBAS

Contact:

Prof. Vasil Ivanov Kavardjikov
Institute of Mechanics – BAS (IMBAS)
+359 2 979 64 20,+359 2 979 64 51Institute for Materials Science and Welding, Graz kavarj@imbm.bas.bg


Proposal 10   (top ►)

Project Title

Self-healing elastomeric materials for automotive applications

Sub-Group

SG 2:  Materials for Automotive

Short Summary

The objective of the project is to create new formulations of elastomers with self-healing properties, for their use in automotive applications. The materials will include natural rubber (NR), synthetic rubbers, silicones, thermoplastic polyurethane (TPU), etc. The envisaged applications for these materials include silent-blocks, tubes, wheels, etc. The strategy for the fabrication of self-healing elastomers will consist on using new principles of vulcanization, based on the insertion of reversible bonds on the curing processes.

Contact:

Dr. Hans Grande
IK4-CIDETEC
+34 943 309 022
Parque Tecnológico de San Sebastian.. Paseo Miramón, 196
20009 Donostia - San Sebastián
hgrande@cidetec.es


Proposal 11   (top ►)

Project Title

Thermoplastic leather composite materials for automotive applications

Sub-Group

SG 2:  Materials for Automotive

Short Summary

The objective of the project is to create renewable thermoplastic composites that present the appearance and touch of wood and leather, for the fabrication of interior car components. The strategy for the fabrication of such composites will consist on using renewable materials such as leather scraps or lignin derivatives, in combination with conventional thermoplastic polymers used in the automotive industry. The result of the project will be a new thermoplastic material with good aesthetic and touch properties.

Contact:

Dr. Hans Grande
IK4-CIDETEC
+34 943 309 022
Parque Tecnológico de San Sebastian.. Paseo Miramón, 196
20009 Donostia - San Sebastián
hgrande@cidetec.es


Proposal 12   (top ►)

Project Title

Advanced coatings for high performance magnesium alloy parts

Sub-Group

SG 2:  Materials for Automotive

Short Summary

The objective of the proposal is to develop durable magnesium superlight car parts by using environmentally friendly and easy-to-apply protective coatings. Some of the technologies to apply are plasma electrolytic oxidation and sol-gel coatings. Magnesium alloys have not been extensively introduced in vehicles driven partly by material cost, durability concerns such as high temperature creep or distortion and corrosion problems. There is a need to develop new durable magnesium based alloys and protective coatings that will enable the widespread use of light magnesium alloys for different applications in the automotive industry and this project is aimed at approaching these aspects.

Contact:

Dr. Eva García-Leciña
IK4-CIDETEC
+34 943 309 022
Parque Tecnológico de San Sebastian.. Paseo Miramón, 196
20009 Donostia - San Sebastián
egarcia@cidetec.es


Proposal 13   (top ►)

Project Title

Innovative coatings and surface treatments for low friction aeronautic gears

Sub-Group

SG 1: Materials for Aerospace

Short Summary

The motivation for this research is to respond to aeronautic industry requirements to increase the efficiency of the modern engines, using environmentally friendly processes. An important part of an engine is the transmission. In this context, power transmission equipments employing gears, dissipate significant amounts of power and any improvement in their performance represents a significant reduction in energy consumption. Therefore, the reduction of the friction ratio, keeping or improving the hardness and wear performance has become a subject of great technological and scientific interest.
Different technologies will be investigated:
- (Electro) deposition of multifunctional metallic coatings (alloys and composites) to reduce degradation due to erosion, to improve anti-friction properties and enhance the life and performance of the components.
- High precision mechanizing by electropolishing to decrease friction and therefore to improve engine propulsive efficiency and reduce fuel consumption.

Contact:

Dr. Eva García-Leciña
IK4-CIDETEC
+34 943 309 022
Parque Tecnológico de San Sebastian.. Paseo Miramón, 196
20009 Donostia - San Sebastián
egarcia@cidetec.es


Proposal 14   (top ►)

Project Title

Coating of C-C composites for ultrasonic vehicles

Sub-Group

SG 1: Materials for Aerospace

Short Summary

To develop materials for hypersonic vehicles. C-C composites are likely materials, but they require the development of coatings with protection capability in excess of ~2000°C.

Contact:

Dr. Andreas Chrysanthou
+44 (01707) 284288 A.Chrysanthou@herts.ac.uk
School of Aerospace, Automotive and Design Engineering, University of Hertfordshire, College Lane, Hatfield, Herts AL10 9AB


Proposal 15   (top ►)

Project Title

Electromagnetic processing of automotive body materials, materials for marine applications, etc.

Sub-Group

SG 1: Materials for Aerospace
SG 2:  Materials for Automotive

Short Summary

To use electromagnetic processing to reduce residual stresses at welded joints, improve corrosion resistance, reduce the problem of springback, etc.

Contact:

Dr. Andreas Chrysanthou
+44 (01707) 284288 A.Chrysanthou@herts.ac.uk
School of Aerospace, Automotive and Design Engineering, University of Hertfordshire, College Lane, Hatfield, Herts AL10 9AB


Proposal 16   (top ►)

Project Title

Catalytic oxidation of carbon-carbon aircraft brakes

Sub-Group

SG 1: Materials for Aerospace

Short Summary

The objective of the project is o understand the mechanisms by which the catalytic oxidation takes place and then to devise methods to prevent it.

Contact:

Dr. Andreas Chrysanthou
+44 (01707) 284288 A.Chrysanthou@herts.ac.uk
School of Aerospace, Automotive and Design Engineering, University of Hertfordshire, College Lane, Hatfield, Herts AL10 9AB


Proposal 17   (top ►)

Project Title

Development of magnesium based composite materials

Sub-Group

SG 2:  Materials for Automotive

Short Summary

The objective of the project is to  develop magnesium reinforced alloys for transport

Applications and to optimise the production of TiC/Al and TiB2/Al master compounds by SHS and their incorporation into AM60 alloy. Analysis of mechanical and thermal properties and modelling of properties

Contact:

Dr. Pedro Egizabal
Tecnalia Research & Innovation. Department of foundry and advanced metallic materials
+34 667116065
Mikeletegi Pasealekua 2, Donostia-San Sebastian 20009
Pedro.egizabal@tecnalia.com

Coordinators:

Dr. Egizabal, Pedro (TECNALIA, Spain)
Dr. Thomas Weissgaerber (IFAM-DD, Germany)

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