Research Unit of Advanced, Composite, Nanomaterials ...€¦ · Research Unit of Advanced,...
Transcript of Research Unit of Advanced, Composite, Nanomaterials ...€¦ · Research Unit of Advanced,...
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Work Group Meeting 16 June 2017, Prague, Czech Republic
Research Unit of Advanced, Composite, Nanomaterials & Nanotechnology
National Technical University of Athens
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Description The National Technical University (NTUA) is the oldest and most prestigious educational institution of Greece in the field of technology, and has contributed unceasingly to the country's scientific, technical and economic development since its foundation in 1836. It is closely linked with Greece's struggle for independence, democracy and social progress. In Greek, NTUA is called the "Ethnicon Metsovion Polytechnion" which stands for National Metsovion Polytechnic. It was named "Metsovion" to honor the donors and benefactors Nikolaos Stournaris, Eleni Tositsa, Michail Tositsas and Georgios Averof, all from Metsovo, a small town in the region of Epirus, who made substantial donations in the last half of the 19th century.
Facts and figures:
9000 undergraduate students, 5-years curriculum 1500 graduate students 550 faculty members 150 laboratory personnel 260 administrative staff 20 Interdisciplinary Postgraduate Courses
Host institute – National Technical University of Athens
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NTUA – Academic Structure
Civil Engineering
Mechanical Engineering
Electrical & Computer
Engineering
Architecture
Chemical Engineering
Rural & Surveying
Engineering
Naval Architecture & Marine
Engineering
Mining & Metallurgical
Engineering
Applied Mathematical &
Physical Sciences
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Connects research carried out by NTUA with the needs and interests of the producing business
Enriches the educational process with relevant experience gained from this connection
(LTCP) - www.ltp.ntua.gr/
NTUA
LTCP
Lavrion Technological & Cultural park
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People
72 faculty members
800 undergraduate students, 160 freshmen each year
400 doctoral candidates
150 graduate students, in two Interdisciplinary
Postgraduate courses on
1) Computational Mechanics
2) Materials Science and Engineering
Structure (Departments)
I. Chemical Sciences
II. Process Analysis and Plant Design
III. Materials Science and Engineering
IV. Synthesis and Development of Industrial Processes
Ranked 101-150 worldwide, 30-40 in Europe,
by QS World University Rankings 2012
http://www.chemeng.ntua.gr
School of Chemical engineering
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Head : Professor Costas Charitidis
People :
• 5 Professors
• 4 Post Doctoral Researchers
• 5 Researchers
• 9 PhD & MSc students
The "Research Unit of Advanced, Composite, Nano Materials & Nanotechnology", R-NanoLab is situated at the School of Chemical Engineering (Department of Materials Science and Engineering) of National Technical University of Athens (NTUA). It is established since 2006; its research group has extensive experience in Design, Production and Characterization of Advanced-, Composite- and Nano- Materials.
Clusters :
• The European Materials Characterization Cluster
• The European NanoSafety Cluster
• The European Materials Modelling Council
• The European Carbon Fibre & Advanced Composites
Technology Cluster
• The European Engineering and Upscaling Cluster
• European Pilot Production and Networking
R-Nano in a nutshell - nanolab.chemeng.ntua.gr
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• Carbon based micro(nano)structures (CNTs, CNFs, CFs, graphene etc)
• Core and Core/Shell nanoparticles
• Polymer matrices (epoxy, PDMS, etc)
• Synthesis and characterization of novel composite materials
• Materials modeling (atomistic, mesoscopic, macroscopic)
• Innovative measurement techniques in the field of materials science
• Composite materials for the construction industry
• Biomaterials
R-Nano | main research activities
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• Carrier Frame and Brake system construction (increase accuracy of applied tension - accomplished)
Stabilization process of PAN fiber • continuous process of fiber
• set up of different temperature profiles (e.g. 180/220/260/290°C)
• set up of different tensions profiles (e.g. 7/7/5/3.5N)
•minimize deviation of real and set values (±0.5oC and ±0.1N)
• production rate 0.4 - 4.0m/min • fully automated system
R-Nano | Continuous stabilization line
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R-Nano | pilot melt spinning line Installation of Compressed Air units & network Twin screw extruder, volumetric hoper and multifilament
Air quench cabinet, winding and take-up system
• Compressed air supply vital for system operation • Installation of 16.8m3/h air supply at 6 bar pressure for
multifilament operation • Soundproof vertical air receiver compressor • Installation of 60m3/h air supply at 11 bar pressure for reversed
venturi air gun • TUV certified CE 97/23
Spin fibers extrusion downwards through vertical cooling tunnel. Each godet temperature Speed of each godet and coupling factor are individually programmable Stretching ratio from godet to godet is also programmable
• Lab Extruder Ø20 mm with an overall processing length of 25 L/D
• Integrated melt pump (gear pump) and melt valve as a bypass system
• Output range: 0.3 up to 2.5 kg/h with extruder Ø 20 mm • Production rate 100 - 500 m/min • Temperature control for each godet (4 x) • Speed control for each godet (4 x) • Stretching ratio from godet to godet (4 x)
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Corrosion testing
A complete array of conventional electrochemical techniques and spatially resolved electrochemistry is made available for full assessment of the corrosion resistance.
Concerning passivation, corrosion onset and corrosion healing, Electrochemical Impedance Spectroscopy, DC Polarisation, Scanning Vibrating Electrode Technique and Localized Electrochemical Impedance Spectroscopy will be used to study the response of fine graded intermetallic base parts.
Atomic Force Microscope equipped with an extra electrochemical cell will be used to monitor in-situ topographical changes
due to electrochemical reactions.
R-NANO Research Unit | NTUA - Facilities
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Overlapping roles of nano-indentation, micro-indentation and tensile tests.
Elastic and plastic
response
Elastic response
Nano-indentation
Tensile test
Plastic response
Micro-indentation
R-NANO Research Unit | NTUA - Facilities
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R-NANO Research Unit | NTUA - Facilities
Lower heating stage
Upper heating stage Upper heating stage
Sample mounting stage
Upper heating stage
Lower heating stage
Sample
Transducer
Indenter tip holder
Protective cap
Indenter probe
xSol High Temperature Stage, Hysitron Inc. Measurements from RT 800C at stable temperature conditions
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R-NANO Research Unit | NTUA - Facilities
Lower heating stage
Granite base
Transducer
Automated
X-Y stage
Protective cap Optical lens
Optical fiber
Sample mounting
stage
Cooling liquid
hose
CCD camera
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R-NANO | Running projects
A novel process for manufacturing complex shaped
Fe-Al intermetallic parts resistant to extreme environments
The research leading to these results has received funding from European Community’s HORIZON 2020 framework programme for research and innovation under GA Ν◦ 689510
equ
inox-p
roject.eu
Work Group Meeting 16 June 2017, Prague, Czech Republic
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equinox-project.eu
The research leading to these results has received funding from European Community’s HORIZON 2020 framework programme for research and innovation under GA Ν◦ 689510
Outline
o The consortium
o Objectives and impacts
o State of the Art
o Methodology
o Work Package structure
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equinox-project.eu
The research leading to these results has received funding from European Community’s HORIZON 2020 framework programme for research and innovation under GA Ν◦ 689510
Consortium - Responsibilities
Participant No * Participant organisation name Country Type Responsibilities
1 National University of Athens (NTUA) GR RTO Mechanical testing
2 TEKON DE SME Demonstrators
3 Dr. Kochanek Entwicklungsgesellschaft (KE) DE SME Preforms
4 IMDEA ES RTO Infiltration
5 TU-Liberec (TUL) CZ RTO Heat treatment,
Microstructure
6 Access DE RTO Modeling, Simulations
7 Open Source Management (OSM) UK SME Dissemination
8 CES Operations (CES) NO SME Demonstrators
9 Freni Brembo S.p.A (BREMBO) IT Industry Demonstrators
10 Yuzhnoye (YUZ) UKR Industry Demonstrators, Preforms
11 Innovation in Research and Engineering Solutions (IRES) BE SME LCA, SbD principles
Prof. C.A. Charitidis (NTUA): Coordinator
Dr. W. Kochanek (KE): Technical coordinator
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equinox-project.eu
The research leading to these results has received funding from European Community’s HORIZON 2020 framework programme for research and innovation under GA Ν◦ 689510
Consortium
Industry (2)
SME (5)
NTUA
Institute (4)
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equinox-project.eu
The research leading to these results has received funding from European Community’s HORIZON 2020 framework programme for research and innovation under GA Ν◦ 689510
Main objective
The main objective of EQUINOX is :
to develop a novel process that allows to substitute Critical Raw Materials
(CRMs) based stainless steel parts used in high volume end consumer
products such as in the lock industry, electronics, process and
automotive industry with a new class of highly advanced ductile Fe-Al
based intermetallics produced by a novel near net shape technology.
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The main objective is supported by the following specific objectives : 1. Produce extremely fine grained FeAl-Material of high ductility via reactive infiltration of
porous iron preforms with liquid Aluminum
2. Understand how ultrafine porous iron structures of complex 3D-shape can be tailored to be used as optimized preforms for reactive infiltration of liquid Al-alloys
3. Develop a reactive infiltration process by using two different techniques: suction and centrifugal casting
4. Simulate reactive infiltration process by physically based multi-scale models based on StarCast and MICRESS
5. Optimize mechanical properties of EQUINOX material with respect to microstructure based on process conditions and consecutive heat treatment
6. Scale up the process from lab to small pilot plant with respect to the industrial needs
7. Transfer the concept to at least one real demonstrator which will be tested for high corrosion and wear resistance
8. Evaluate the industrial impact of EQUINOX-concept with respect to economic as well as technical aspects.
equinox-project.eu
The research leading to these results has received funding from European Community’s HORIZON 2020 framework programme for research and innovation under GA Ν◦ 689510
Specific objectives Lab
orato
ry scale . . . an
d b
eyon
d
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equinox-project.eu
The research leading to these results has received funding from European Community’s HORIZON 2020 framework programme for research and innovation under GA Ν◦ 689510
Main impact
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equinox-project.eu
The research leading to these results has received funding from European Community’s HORIZON 2020 framework programme for research and innovation under GA Ν◦ 689510
Main impact
M A I N I M P A C T EQUINOX would allow to save at least 18.000 Tons of CRM per year by substituting stainless steel
through CRM free Fe-Al based intermetallics (even without considering stainless steel flat products)
First conclusion: Substitution potential of stainless steel may be found in the market sector of “long product” which represents a volume of 6.6 Mio t p.a.
Flat products: attributing for 29.4 Mio t p.a. (82 % of the market) Long products: attributing for 6.6 Mio t p.a. (18 % of the market)
Second conclusion: the economic impact of EQUINOX would be equivalent to a substitution of 290 Mio € p.a. of semi-finished stainless steel products.
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equinox-project.eu
The research leading to these results has received funding from European Community’s HORIZON 2020 framework programme for research and innovation under GA Ν◦ 689510
State of the Art (Steel Industry)
Step 1 Step 2
Step 3
Step 4
• A lot of energy is wasted • Major sources for CO2 emissions
• 43% is scrap material
• High transportation costs
• High transportation costs
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equinox-project.eu
The research leading to these results has received funding from European Community’s HORIZON 2020 framework programme for research and innovation under GA Ν◦ 689510
State of the Art (Intermetallics)
The major problem with many intermetallics is their low ductility at ambient temperatures.
Before intermetallics can substitute stainless steel as structural materials in high volume markets, they have to be modified to improve their ductility,
without scarifying their strength and inherent corrosion and wear resistance.
Production technologies must be developed to translate these unique properties into technical products of complex 3D-geometry.
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equinox-project.eu
The research leading to these results has received funding from European Community’s HORIZON 2020 framework programme for research and innovation under GA Ν◦ 689510
The research strategy focuses on the structural factors at the submicron level
A new concept beyond sheer material composition
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equinox-project.eu
The research leading to these results has received funding from European Community’s HORIZON 2020 framework programme for research and innovation under GA Ν◦ 689510
Methodology
1. Fe porous preform 2. Al infiltration
3. Simulation
MIM SLM KE
Pressureless Pressure assisted
4. Subsequent heat treatment
5. Corrosion and mechanical testing
Microscopic Macroscopic
Phase tailoring Particle size tailoring
Optimization loop
6. Industrial demonstrator building
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equinox-project.eu
The research leading to these results has received funding from European Community’s HORIZON 2020 framework programme for research and innovation under GA Ν◦ 689510
Work Package structure
WP1Porous
preforms
WP2Infiltration by liquid
Al
WP3Modelling
(Thermodynamics, kinetics)
WP4Microstructure, Heat treatment
WP5Corrosion,
Mechanical testing
WP6Demonstrator
WP7: Safe by Design - LCA WP8: Dissemination WP9: Management
WP2
WP1
Modify Al-melt tocontrol kinetics ?
Modify particlesurfacetocontrol wetting and kinetics ?
WP4
WP5
1.
2.
WP6 WP7
WP3
Op
tim
ized
Fe-
Al-b
ased
pa
rt
Te
sti
ng
De
mo
nst
rato
rs
Complex 3D-shaped part, from iron oxide
Porous preformbased on ultrafine
Fe particles
Porous preform, chemically tailored at
the grain surface
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equinox-project.eu
The research leading to these results has received funding from European Community’s HORIZON 2020 framework programme for research and innovation under GA Ν◦ 689510
Milestones timeline
Milestone No
Milestone name Related
WP(s)
Estimated date
Means of verification
M1Feasibility of pressureless
infiltration2 M6
Definition of the method and the range of preform to
which is applicable
M2 Pressure-assisted infiltration 2 M33Optimal parameters for
pressure-assisted infiltration
M3 Model of Microsimulation 3 M6The model for microstructure
simulation is working
M4 Post heat treatment 4 M30Recommendation for the optimal
heat treatment processM5 First prototypes ready 6 M24 Produced piecesM6 Prototype approval 6 M32 Industrial testing results
M7 Industrial development 6 M36Road map and industrial scaling
reports
Feasibility study of one of the
methods for Al infiltration
Verification of the simulation
model reliability
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Thank you for your attention
Work Group Meeting 16 June 2017, Prague, Czech Republic
National Technical University of Athens