NanoDiamond Composites With Enhanced Thermal and Mechanical Properties: Hard as Hell, but Cooler

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1 NanoDiamond Composites With Enhanced Thermal and Mechanical Properties: Hard as Hell, but Cooler Advanced Engineering UK 2016 Netcomposites Forum Gavin Carbodeon Ltd. Oy.

2 Driving Technology udiamond NanoDiamonds Production from detonation stage onwards Industrial supplies with established accounts Continuous development of new nanodiamond grades/ variants Applications development to support new business in nanodiamond material sales Nicanite Carbon Nitride HQ in Finland, Helsinki Region Established 2006 Sales on 5 continents

3 Next gen. product specs Not strong enough Thermal properties Material selection: Compromise.. Material selection: Compromise.. Too brittle Regulatory Issues Doesn t fit manufacturing Other problems Too expensive Material design: Combine, Optimise.. Base Material Something Extreme! Selected ratio.. Property Combination + NanoScale Effect Optimised properties, process, cost.

4 Carbodeon NanoDiamond Extreme Material. Strength Hardness Surface Friction Chemically Inert Optical Properties Dielectric Thermal Conductivity With some unusual combinations

5 NanoComposite Requirements thermal conductivity, and electrical isolation faster, and cheaper Improve property A without compromising property B in parent material X..in our existing process more power and better economy less energy and more light better polished finish same material removal wear, and corrosion resistance lighter, but with the same failure modes

6 NanoComposite Requirements thermal conductivity, and electrical isolation faster, and cheaper Improve property A without compromising property B in parent material X..in our existing process more power and better economy less energy and more light (Almost) Never the same question twice! better polished finish same material removal wear, and corrosion resistance lighter, but with the same failure modes

7 The Nanocomposite Challenge Nanomaterials Implementation Practicality Parent Materials Processing Methods & Supply Chain

8 Nanodiamond Materials Detonation Synthesised 4-6 nm diamond particles Proven industrial process: tonnes/ yr scale Sp3 Diamond Core Graphitic facets With surface functional groups

9 Hydrophilicity udiamond Portfolio The Carbodeon Difference O 2 N CH 3 OC CONH 2 OH NH 2 Application-designed HS H COOH Tuned surface chemistry, no surfactants used Dispersion/Agglomeration control Dispersion media options COOH High purity H ROHS compliant REACH Member of Diamond Consortia NH 2 Oleophilicity Active own application development Z Electroplating IPR Thermal management Polymer composites Reduced consumption, reproducibility and cost efficiency R

10 udiamond Amine P & D NH2 New, patented highly zeta positive nanodiamond powder and dispersion with strong particle interaction Fully amine functionalized surface Hydrophobic Strong stability in solvents Launched 2015 Morphology Powders Dispersions in GBL, NMP, NEP, DMA, more on the way In-house and customer application development in thermoplastics since 2013 and thermosets since 2015

11 udiamond Portfolio Options for surface chemistry and morphology Powders - agglomerated clusters of NanoDiamonds in micron scale. Used where no compatible solvent available, e.g. thermoplastics and many thermosets Suspensions smaller agglomerates in liquid, easier to incorporate. Dispersions single digit 4-6 nm particles in stable dispersion Very easy dispersion direct mixing Increased surface area Low concentrations wt%, <1g/litre (in cases)

12 Morphology 5% 0.5% Detonation Soot NanoDiamond Powder NanoDiamond Suspension NanoDiamond Dispersion

13 Parent Materials Coatings Metals Thermoplastics Thermosets

14 Parent Materials - Metals Nanodiamond suspension or dispersion added to plating solutions Finer grain structure + embedded hard particles 3. Electroless nickel: Abrasion resistance tripled 2. Gold plated electrical connectors: wear performance improved by 100% 1. Industrial machine parts with hard chrome: durability improved from 3.5 to 5.5 years

15 Parent Materials Solvent or Aqueous Coatings NanoDiamond powder, suspension, or dispersion Hard particles bonded to parent material. Polymer reinforced/ restructured at molecular scale 1. PTFE and FEP coatings aqueous and solvent. Wear improvement up to 50% Friction reduction up to 66% Surface finish improved 85% 2. Consumer product: unnamed coating formulations on unnamed products: Wear performance improved by >3X

16 Mass reduction (mg) Wear Properties PTFE (Aqueous) Taber analyses Cycles REF. PTFE_REF PTFE - #1 1.0wt% PTFE_KT - #1 AGGLOM. ND 0.1wt% PTFE_Ktsingle - #1 SINGLE DIGIT DISPERSION ND concentrations, in final coatings Agglomerating grade, 1 wt.% Single Digit grade, 0.1 wt.% Wear properties studied up to cycles Up to 50% improvement in wear properties, up to 66% friction reduction

17 Mass reduction (mg) Wear Properties PTFE (Aqueous) Taber analyses Cycles REF. PTFE_REF PTFE - #1 1.0wt% PTFE_KT - #1 AGGLOM. ND 0.1wt% PTFE_Ktsingle - #1 SINGLE DIGIT DISPERSION ND concentrations, in final coatings Agglomerating grade, 1 wt.% Single Digit grade, 0.1 wt.% Dispersion material Less is More! Wear properties studied up to cycles Up to 50% improvement in wear properties, up to 66% friction reduction

18 Friction coefficient Friction Properties PTFE (Aq) Allegro Friction coefficient averages R ND concentration (wt.%) Friction tests with Allegro ND not the latest single digit dispersion ND concentrations varied between 0.1 to 3.0 wt.% Significant improvements already with very low ND additions 66% reduction received with 2 wt.% ND concentration

19 Friction coefficient Friction Properties PTFE (Aq) Allegro Research data indicates % fuel consumption saving when applied to automotive pistons compared to standard PTFE Friction coefficient averages R ND concentration (wt.%) Friction tests with Allegro ND not the latest single digit dispersion ND concentrations varied between 0.1 to 3.0 wt.% Significant improvements already with very low ND additions 66% reduction received with 2 wt.% ND concentration

20 Thermoplastics Nanodiamond powders added to existing polymers & composites Thermal conductivity without compromise to other properties Electronics & LED Thermoplastic Heat sinks: Thermal & dielectric properties Thermoplastic Development: Thermal conductivity increased % with 0.1wt% NanoDiamond Low Carbon Vehicles: Additional structural, lightweighting &Tg possibilities

21 PA-66 Thermal Compound, 45 wt.% Overall Loading References: neat PA-66 compound with 45 wt.% BN loading Processing: Carbodeon proprietary Performance (W/m. K): 0.05 wt.% 0.1 wt.% 36.3% improvement within inplane thermal conductivity 29.4% improvement within average thermal conductivity 51.4% improvement within inplane thermal conductivity 38.2% improvement within average thermal conductivity PA-66 Ref in-plane (x/y) average (x/y/z)

22 PA-66 Electrically Conducting Thermal Compound, 50 wt.% Overall Loading References: neat PA-66 compound with 50 wt.% graphite loading Graphite filler material, TIMCAL TIMREX KS5-75TT Primary Synthetic Graphite Performance: 0.5 wt.% 46.3% improvement within in-plane thermal conductivity 40.7% improvement within average thermal conductivity in-plane (x/y) average (x/y/z) Works with a variety of fillers. 0 PA-66 Ref

23 PA-66 Electrically Conducting Thermal Compound, 50 wt.% Overall Loading References: neat PA-66 compound with 50 wt.% graphite loading Graphite filler material, TIMCAL TIMREX KS5-75TT Primary Synthetic Graphite Performance: 0.5 wt.% 46.3% improvement within in-plane thermal conductivity 40.7% improvement within average thermal conductivity in-plane (x/y) average (x/y/z) Works with a variety of fillers. 0 PA-66 Ref In next steps, some research has been done on mechanical properties. Combination with other mechanical fillers (micron or nano scale) can be expected to yield results also.

24 Thermosets Nanodiamond powders added to existing polymers & composites Wide range of thermal and mechanical properties to modify Abrasion resistance of resins including resins used in composites Electronics & LED Silicone and epoxy thermal interface materials Various thermal, mechanical and failure properties in composites.

25 Project Approach Material and Process Understanding NanoDiamond Material Selection (functionalisation) Dispersion Methods & Process Optimisation Property Requirements, Test Methods, Economics Communication

26 Conclusions Extremely small amounts of nanodiamond additives can modify a variety of thermal and mechanical properties in various parent materials Hard as Hell, but Cooler Success factors Dispersion / agglomeration control : surface area is an essential property Surface functionalization has to be appropriate Combination with other micron or nano scale materials. Hierarchy Project based approaches Actions: Consider the possibilities of nanodiamond materials within your material development/ product development activities now and in the future Form good networks between nanomaterial, polymer, coating, composite, component, system and OEM parties Out of the box thinking, focusing on high value solutions Carbodeon patents covering aspects of the material - its preparation and properties, and many of the applications

27 Carbodeon Ltd. Oy Pakkalankuja Vantaa Finland Gavin Farmer Business Development Mobile: gavin.farmer@carbodeon.com Vesa Myllymäki Chief Technical Officer Mobile: vesa.myllymaki@carbodeon.com