HYbrid sintering and advanced MAchining of technical CERamics Grant Agreement no: 606390 7th Framework Program Research for SMEs (SME-2013-1) Coordinator: Prof. B. Lauwers, KU Leuven, Belgium Project Officer: Mrs. Maciej Lopatka
Consortium RTD Katholieke Universiteit Leuven PMA / MTM / LRD RTD Centro de Investigación en Nanomateriales y Nanotecnología SME Nanoker research SL SME FCT Systeme GmbH BE NL SME CERATEC Technical Ceramics BV DE SME SMS Stamp Tool & Mould Technologies BV ES RTD Advanced Manufacturing Technologies 2
Technical ceramics Outstanding combination of physical, mechanical and thermal properties o o o Corrosion resistance High temperature resistance Wear resistance 2015 15.5 billion $ market Why fine graine Y-ZrO 2 -and Al 2 O 3 -based electrically conductive composites? o o o Improved strength (fine grain sizes) Improved fracture toughness (crack deflection) Improved thermal and electrical conductivity (secondary phases) 2 µm 2 µm Al 2 O 3 Al 2 O 3 -WC (60/40) (vol%) 3
Problem Statement RTD Level Proven @ Lab Scale Material Development Sintering Technology Machining Technology 1 cm Ceramic Composite Micro Gear SME Level SME s needs for a competitive advantage Upscaled Sintering Technology Large scale ceramic blanks Advanced Machining Strategies 10 cm 1 cm Ceramic Pump Component 4
Approach Technology oriented o o o o Defined material composition (ZrO 2 -WC/TiN, Al 2 O 3 -Ni-TiC-SiC) Up-scaling hybrid FAST/SPS technology Process modeling and experimental verification Broad machining technologies portfolio and material-process investigation Market oriented o Selected case studies from the SMEs core business KnowledgeTransfer 5
Overall Objective Development of a SME scale, cost effective and complete supply chain for processing and machining large scale innovative ceramics blanks and products Process Value Chain Equipment Modeling Powder preparation Material characterization EDM, USM, ELID grinding Process evaluation Design Manufacturing Testing Processing Technology Material Development Machining Technology Product Development Partners: Partners: Partners: Partners: FCT KUL-MTM KUL-MTM CINN-CSIC NANOKER KUL-MTM CINN-CSIC KUL-PMA TEKNIKER CERATEC Artooling KUL-PMA TEKNIKER CERATEC Artooling 6
Specific Objectives O1: Economical SME-scale processing route for oxide based, conductive ceramic composites O2: Large scale ceramic blanks O3: Hybrid SPS Model O4: Efficient Machining Strategies O5: New/Enhanced Ceramic Engineering Applications 7
Case Studies Punches and dies for progressive stamping Exploiter: Artooling; Market : Automotive; Material properties: ZrO 2 -TiN and ZrO 2 -WC, high wear resistance and strength, thermal conductivity, dry processing. Requirements: 180 N/mm 2, 450 strokes/min; Ra 0.3-0.4µm, tol. ±0.005 mm, complex shapes, sharpness Cutting tool inserts Pump components Exploiter: Ceratec; Market: Automation; Material properties: Al 2 O 3 -Ni-TiC-SiC, ZrO 2 -TiN corrosion-wear resistance, fracture toughness and strength. Requirements: life> 36 months, 75 Nm, low ph, 80 C, Ra 0.07 µm, tol.-8/-15 µm. Exploiter: Nanoker; Market: Manufacturing; Material properties: Al 2 O 3 -Ni-TiC-SiC, ZrO 2 -TiN chemical-wear resistance, thermal conductivity, fracture toughness and hardness. Requirements: dry machining, sharpness, tol. 5 µm 8
Innovative Aspects Economical breakthrough (market oriented) Large scale, highly innovative ceramic composite blank Novel use of ceramics Enhanced products with improved physical and mechanical properties Technological breakthrough Fast and homogeneous sintering of large, difficult-to-densify ceramics High quality, efficient sintering using hybrid SPS technology Multiphysics modeling, coupled thermal-electrical-magnetic FE modeling Advanced (ceramics) machining strategies Enhanced machining performance through improved understanding of material-process interaction 9
Project Structure KUL-MTM CINN-CSIC Nanoker KUL-MTM CINN-CSIC Nanoker FCT KUL-PMA Tekniker Artooling Ceratec FCT Ceratec Nanoker Artooling RTDPs Material Processing & Characterization Powder preparation Material characterisation Hybrid SPS Technologies FE modelling Experimental validation and sintering Hard Machining Technologies EDM, USM, ELID-Grinding Roughing-super-finishing Demonstration Large scale ceramic blanks Stamping tools and dies Pump components Cutting tools WP1 WP2 WP3 WP4 WP5 Dissemination & Exploitation KULeuven, CINN-CSIC, Tekniker, Nanoker, FCT, Artooling, Ceratec WP6 Project Management KUL-PMA 10
Task breakdown and project timing 11
Expertise (Micro-) EDM of ceramics, high speed micro-milling, hard turning, USM, ELID grinding, design and analysis of experiments, surface characterization Role: Project coordinator, WP6 leader WP3: EDM and advanced cutting of ceramics, material/process interaction investigation and technology tables / WP4: Support on product Development / WP5: dissemination and training Expectation New knowledge and experience in ceramic machining Improved insights in material-process interaction Improved machining and manufacturing strategies Dissemination: high IF publication, education, future project 12
Expertise Ceramic processing (powder synthesis, colloidal processing, sintering), lab scale Spark Plasma Sintering, microstructural characterization, mechanical property testing, multiphysics modeling Role WP1: processing and characterization of Y-ZrO 2 based ceramic composites, characterization of machined ceramics / WP2: development and experimental verification of coupled thermal-electrical-magnetic FE model / WP4: assist in hybrid sintering tests for case studies / WP5: dissemination and training Expectation broadening knowledge and understanding on hybrid spark plasma sintering broadening FE modeling skills, especially wrt coupled multiphysics modeling establishing know-how on electrical field assisted sintering processes dissemination of results in scientific journals and congresses 13
Expertise Ceramic processing (powder synthesis, colloidal processing, sintering), lab scale Spark Plasma Sintering, microstructural characterisation Role WP1: processing and characterisation of Al 2 O 3 based ceramic composites, characterisation of (hybrid) SPS densified materials / WP2: sintering of Al 2 O 3 and ZrO 2 -based large scale ceramics composites blanks/ WP4: assist in hybrid sintering tests for case studies / WP5: dissemination and training Expectation Deeper scientific knowledge on electroconductive ceramics Strengthening knowledge on SPS sintering Becoming a European competence center in the development of ceramic materials for Hybrid SPS-HP sintering technologies Dissemination of results in scientific journals and congresses 14
Expertise Product/process development, unconventional machining, material characterization Role: Gender Equality Manager WP3: Machining technologies for final shaping of new ceramics and components with complex geometries through, rotary ultrasonic machining and laser machining for small features or texturing processes, material and surface integrity evaluation (residual stresses, roughness, damage ) / WP4: support on product development / WP5: dissemination and training. Expectation Improvement of expertise in machining processes and applications of ultrasonic technology Knowledge transfer to industry of the developed knowledge Dissemination of results high IF in journals and congresses Future project opportunities 15
Expertise IP Nanoker: best european project award, large ceramic powder batch preparation, owner of world s largest hybrid SPS apparatus Role: WP1 leader / Dissemination & Exploitation Manager WP1: Processing of powders at an industrial scale / WP2: SPS hybrid sintering at an industrial scale of ceramic blanks (ϕ 400 mm) / WP4: assess the use of the hybrid sintered Al 2 O 3 -Ni-TiC-SiC composites as indexable cutting tool inserts for machining operations and will provide large sized oxide based composite blank parts for further machining operations / WP5: Dissemination and exploitation Expectation Manufacturing and commercialization of new brands of ZrO 2 and Al 2 O 3 ceramic blanks obtained by SPS and manufacturing and commercialization of Al 2 O 3 composite cutting tools Technology advantage over competitors and increase turnover by an estimated 40%. 16
Expertise Builder of European SPS prototype (FAST HP 25/D), commercialization of (hybrid) SPS furnaces, up-scaling technology, FE modeling, tool design Role: WP2 leader WP1: Processing of powders at an industrial scale / WP2: Support on boundary conditions definition + performing supporting hybrid SPS experiments in their in house hybrid system + experimental verification of KU Leuven developed FE model / WP4: assist in the production of blanks for the case studies / WP5: Dissemination and exploitation Expectation better theoretical and practical understanding of the hybrid heating concept hybrid user tool increase market share in hybrid sintering equipment 17
Expertise Hard machining of ceramics, ceramic product & process design (CAD, CAM, FEM), quality engineering (CMM) Role: WP3 leader WP3: monitoring and coordination of the hard machining activities in the project, providing specifications on machining requirements WP4: join the design, manufacturing and testing demonstration activities of engineering components for the pump industry / WP5: dissemination and exploitation activities Expectation innovative ceramic grade material blanks for advanced pump components to further expand its market position (nominally doubling its current turnover 600 000 EUR within 7 years), as a worldwide supplier custom-made ceramic components. 18
Expertise designer and manufacturer of high speed, complex discrete and modular progressive tools, dies and moulds, manufacturer and user of stamping tool equipment, quality control, wire EDM & hard machining, manufacturing automation (CAD, CAM, PDM) and optimization Role: WP4 leader WP3: support the other SME participants in hard machining activities that can include wire and sink EDM, flat-, profile- and jig-grinding and hard turning / WP4: will define requirements for stamping tool components, will design, manufacture and test ZrO 2 -based industrial machining components with the main focus on components for stamping tools / WP5: dissemination and exploitation activities Expectation Competitive advantage through exploiting ZrO 2 -TiN/WC ceramic compositions for stamping tools and dies and machining technology 15% of stamping and forming tool made from the new materials (7 years scenario) 19
Project results acquired by SMEs PR nr O1 O2 O3 O4 O5 Subtotal Rem. Total Rem. Type of Expl. Ownership Ownership other IPR protection other IPR protection Ownership Nanoker FCT Ceratec ARTOOLING Rem. ( ) Share (%) 124 670 27% 69 261 15% 106 201 23% 69 261 15% 92 348 20% Type of Expl. other IPR protection other IPR protection Ownership other IPR protection Rem. ( ) Share (%) 44 937 15% 44 937 15% 158 777 53% 50 929 17% Type of Expl other IPR protection Ownership Ownership Rem ( ) Share (%) 81 649 30% 95 257 35% 95 257 35% Type of Expl other IPR protection Ownership Ownership 461 742 299 580 272 163 279 208 1312693 Rem ( ) Share (%) 83 762 30% 97 723 35% 97 723 35% O1: SME-scale hybrid Fast/SPS processing O2: Large scale ZrO 2 - and Al 2 O 3 -based hybrid sintered ceramic blanks O3: Thermo-electromagnetic FE modeling of hybrid SPS sintering technology O4: Advanced ceramics machining strategies and technology tables O5: Ceramics blanks and product prototypes 20
Resources Total cost: 1 855 465 RTD subcontracting: 1 312 692.50 EU requested funding: 1 443 933.38 21
Resource allocation Partners costs including invoices Invoices to receive by RTD OWN total eligible costs Max EU Contribution on Partners costs Grant retained by Partners after RTD invoice payment Net SMEPs investment "In kind" Nanoker 627.261,83 461.741,83 165.520 474.226,37 39.372,26-126.147,74 FCT 345.419,67 299.579,67 45.840 264.924,75 11.811,68-34.028,32 Ceratec 345.603,39 272.163,39 73.440 256.302,54 18.373,72-55.066,28 Artooling 347.247,61 279.207,61 68.040 258.555,71 17.061,31-50.978,69 PMA-KUL 116.160,00-374.240 116.160 42.653,28-73.506,72 MTM-KUL 28.480,00-425.280 28.480 656,20-27.823,80 CSIC 21.610,00-407.982 21.610 656,20-20.953,80 TEKNIKER 23.674,00-295.114 23.674 656,20-23.017,80 Total 1.855.456,50 1.312.692,50 1.855.456,50 1.443.933,38 131.240,88-411.523,13 Upper limit on total EU contribution 110% * 1.312692,50 = 1.443.961,75 22