FUTURE MATERIALS MADE BY TODAY S PEOPLE CELLS FOR MATERIALS AND ADVANCED MATERIALS FOR ENERGY APPLICATIONS

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1 FUTURE MATERIALS ADVANCED MATERIALS FOR ENERGY APPLICATIONS INNOVATIVE AND SUSTAINABLE POLYMERIC MATERIALS CELLS FOR MATERIALS AND MATERIALS FOR CELLS MULTIFUNCTIONAL SURFACES LIFE CYCLE THINKING CHARACTERIZATION PLATFORM MADE BY TODAY S PEOPLE

2 Workshop OpP3D Powder Treatment and Alloys for 3D Printing technique and applications Dr. Axel Hemberg May 8th, 2018 Schwäbisch Gmünd/Germany

3 Outline: Materia Nova Research Center Skills Our process Some applications May 8th, 2018 Schwäbisch Gmünd/Germany - 1

4 Outline: Materia Nova Research Center Skills Our process Some applications May 8th, 2018 Schwäbisch Gmünd/Germany - 1

5 Materia Nova premises Since 2000 Non-profit organization 85 > employees Turnover: 8,5 Mio Pure project financing 2011: member of EMRA May 8th, 2018 Schwäbisch Gmünd/Germany - 2

6 Market-driven approach from Lab. to Fab. Innovative Idea «from the idea to the industrialization» Research Project Scientific Valorization Technical Feasibility Design of Equipment Validation at Lab Scale people 300 Process Up-Scaling Pre-series and Production Equipment / Product Sales May 8th, 2018 Schwäbisch Gmünd/Germany - 3

7 High-level scientific activity in UMons Source : Thomson Reuter Academic ranking (2010) Rank 18: Pr. Philippe Dubois Rank 84: Pr. Jean-Luc Bredas Renowned academic! May 8th, 2018 Schwäbisch Gmünd/Germany - 4

8 Some of our industrial partners May 8th, 2018 Schwäbisch Gmünd/Germany - 5

9 MULTIDISCIPLINARY FIELDS OF EXPERTISE AT A GLANCE Plasma technologies Electrochemistry Sol-Gel Energy Management Structured surfaces Dry/Wet Surface Treatments Nanotechnologies Materials Analysis Innovative Polymers Polymers (Nano-)composites Biopolymers Optronic Materials Biotechnology Modelisation Synthesis Devices Biodegradation May 8th, 2018 Schwäbisch Gmünd/Germany - 6

10 MULTIFUNCTIONAL SURFACES Technologies DRY COATINGS (PLASMAS) WET COATINGS Low pressure plasmas PVD magnetron sputtering PECVD µwaves systems High pressure plasmas Torches DBD µwaves Ionic Irradiation and Implantation Electrochemistry Electroplating Anodization Electropolymerization Hybrid organic-inorganic coatings Formulation (sol gel) Application (dip, spray ) Temperature or UV curing Composites: addition of nanofillers May 8th, 2018 Schwäbisch Gmünd/Germany - 7

11 MULTIFUNCTIONAL SURFACES Substrates o Metals / painted metals o Polymers o Glass Geometries o Flat substrates o Foils o Powders o Beads and small parts o Complex parts May 8th, 2018 Schwäbisch Gmünd/Germany - 8

12 MULTIFUNCTIONAL SURFACES Protective Coatings o Corrosion protection o Barrier effect (gas, water, etc) o Wear and scratch resistance o High temperature applications o UV resistance Aesthetics & Cleanliness o Self-cleaning o Easy-to-clean, anti-finger print o Anti-dirtying and anti-graffiti o Anti-microbial transparent coatings for domestic or medical applications o Anti-fouling Without sol gel With sol gel Easy to remove May 8th, 2018 Schwäbisch Gmünd/Germany - 9

13 MULTIFUNCTIONAL SURFACES Active Coatings o Sensors o Catalysis / depollution o Control Solutions for Energy Management o l-selective, passive & active, opto-thermal-electronic materials & devices Optical reflectors/absorbers, AR, low-e windows, superblack, X-chromic, solid-state and organic devices ) o Energy harvesting, storage & conversion solutions PEMFC parts, batteries, power to fuel o May 8th, 2018 Schwäbisch Gmünd/Germany - 10

14 Outline: Materia Nova Research Center Skills Our process Some applications May 8th, 2018 Schwäbisch Gmünd/Germany - 11

15 Outline: Materia Nova Research Center Skills Our process Some applications May 8th, 2018 Schwäbisch Gmünd/Germany - 12

16 In needs of new powders Unusual alloys Core shells structures Enhanced processes For R&D or niche markets And no atomizer plants at home. Magnetron sputtering May 8th, 2018 Schwäbisch Gmünd/Germany - 13

17 Plasma ionized gas made up of electrons, ions, neutral atoms, molecules, radicals (emits photons) > 90 % of the matter in the universe (from interior of stars to outer space) Plasmas inconspicuous on Earth 4 th state Aurora borealis 3 states Lightning Sun Generated in laboratories and industries May 8th, 2018 Schwäbisch Gmünd/Germany - 14

18 2 categories of plasmas: Plasmas in thermodynamic equilibrium All the particles have the same temperature (T e = T ions = T neutrals ) Macroscopic temperature reaches several times 10 4 K (hot plasmas) e.g. stars, electric arcs, plasma jets, nuclear fusion experiments, etc Plasmas in non-equilibrium (10-4 < ionization degree < 10-1 %) Of particular interest for technological applications (laboratories and industries) Each kind of particles (own energy) T e = several times 10 4 K while T neutrals T ions 300 K = T gas (cold plasmas) Electrons = energy vehicles of the plasma Cold plasma in our laboratories! May 8th, 2018 Schwäbisch Gmünd/Germany - 15

19 Categories of cold plasma processes: Cold plasma technologies Homogenous processes Heterogeneous processes e.g. Synthesis of O 3 from O 2 Thin film deposition Etching Grafting Plasma-assisted Physical Vapour Deposition (PVD) Plasma-enhanced Chemical Vapour Deposition (PECVD) Magnetron sputtering May 8th, 2018 Schwäbisch Gmünd/Germany - 16

20 Cathodic magnetron sputtering: Reactor under high vacuum (10-6 Torr) Argon introduction 3 < working pressure < 20 mtorr Magnetic field (B) superposed to electrical field (E) and modifies the electron trajectory + Substrat e Ar ionization in the cathode vicinity deposition rate ( λ ~ 1 cm) film density (quality) Argon Ar + e - e - Ar + e - e - Ar + e - Applications Au, Ag optics (mirror, IR reflector) TiN TiCN TiN decoration, on cutting tools, TiAlN drill bits, etc. - Target N S N Voltage (DC, RF, etc.) May 8th, 2018 Schwäbisch Gmünd/Germany - 17

21 Plasma reactors for powder modification: 1) Rotary plasma reactor: Abbeads Experimental process: Dry process Treatment volume: 0,1-0,5 liters Powders: 0.5 to 500µm Small parts and beads: mm to cm 1 or 2 cathodes; RF Coil All type of coatings (nitrides, carbides, ) Functionalization, Oxidation/reduction May 8th, 2018 Schwäbisch Gmünd/Germany - 18

22 Plasma reactors for powder modification: 2) Rotary plasma reactor: Plameco New Plameco! Experimental process: Dry process Treatment volume: 5 liters Powders: 0.5 to 500µm Small parts and beads: mm to cm 1 or 2 cathodes; RF Coil All type of coatings (nitrides, carbides, ) Functionalization, Oxidation/reduction And now continuous process for 20 tons a year! May 8th, 2018 Schwäbisch Gmünd/Germany - 19

23 Outline: Materia Nova Research Center Skills Our process Some applications May 8th, 2018 Schwäbisch Gmünd/Germany - 20

24 Applications and results in Additive Manufacturing Thermal spraying Technical sealing Composite materials Sintering processes Catalysis. May 8th, 2018 Schwäbisch Gmünd/Germany - 21

25 Core shell structures: For Additive Manufacturing Controlled Coating Improvement of LASER Absorption for high reflectivity and conductivity materials Protection against oxidation, water for sensitive material Enhanced powder flowability for better processing and densities Processable composite powders But also Decreased selective evaporation during E-beam processing Enhanced dispersion of charges during E-beam process May 8th, 2018 Schwäbisch Gmünd/Germany - 22

26 Ex: Powder laser absorption For Additive Manufacturing Figure gives an overview of the laser absorption curves of the Cu-Cr powders (either gas atomized or sputter coated) as a function of the laser wavelength. Table 3. Based on Figure The chromium coating on pure copper powder with drastically increases the laser absorption! The copper powder with small amounts of chromium has a beneficial effect on the laser absorption when comparing gas atomized Cu-Cr powder. May 8th, 2018 Schwäbisch Gmünd/Germany - 23

27 New alloying: For Additive Manufacturing Composition fine tuning for R&D purposes Modification of commercial powders Pseudo alloyed powders no mixing and no alloying process Any elements are now usable (Ti,Cr, B, W, P ) Need some new elements? May 8th, 2018 Schwäbisch Gmünd/Germany - 24

28 Metal coatings of hollow sphere For composite materials Ultra light materials New composite materials for AM? May 8th, 2018 Schwäbisch Gmünd/Germany - 25

29 Sol-gels solutions For composite materials Ceramic sealant Enhanced cohesion and lesser porosity by dip coating New properties Sol-gels based on SiOx, AlOx, ZrOx In development! May 8th, 2018 Schwäbisch Gmünd/Germany - 26

30 Coatings on glass microbeads: For composite materials Ex: Rechargeable Antimicrobial Paint ZnO-Ag films synthesized on glass microbeads Number of bacteria by 500µl as a function of the sample characterized (Staphylococcus Aureus) May 8th, 2018 Schwäbisch Gmünd/Germany - 27

31 New alloys: For thermal spraying Adhesion enhancement on composite materials Improvement of wear resistance and corrosion Improvement of the projection processes May 8th, 2018 Schwäbisch Gmünd/Germany - 28

32 Core shells structure: For technical bonding Ag core shells powders Electrical conductivity of silver Process control enhanced More than 30% of Ag saved And no cyanide baths! May 8th, 2018 Schwäbisch Gmünd/Germany - 29

33 Coating on ceramics powders For sintering processes Ceramics metallization for new composites Oxidation resistance Improvement of final cohesion New aesthetics and technical properties May 8th, 2018 Schwäbisch Gmünd/Germany - 30

34 Metallic nanoparticules on demand For catalysis Improvement of activity Control of the light-off T Control of the selectivity Less material for high specific area Ex: Mo on TiO 2 May 8th, 2018 Schwäbisch Gmünd/Germany - 31

35 Powders but also small parts Balls Bearings Connectors Microsystems May 8th, 2018 Schwäbisch Gmünd/Germany - 32

36 Thank you for your attention Questions?