MATRANS

Micro and Nanocrystalline Functionally Graded Materials for Transport Applications

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 Obiettivo del progetto (Objective)

'MATRANS aims at development of novel metal-ceramic functionally graded materials (FGMs) for aerospace and automotive applications in: (i) exhaust and propulsion systems, (ii) power transmission systems, and (iii) braking systems, with the main objective to enhance the mechanical properties of these materials through spatial variations of material composition and microstructure. Specifically, MATRANS deals with two groups of bulk FGMs: (i) ceramics-copper/copper alloys, (ii) ceramics-intermetallics. These FGM systems have not yet been used in the transport sectors targeted. The MATRANS methodology is problem oriented and comprehensive combining interrelated activities of material processing (core activity of the project), characterisation, modelling and demonstration. The processing will encompass starting materials (e.g. nanopowders) and the resulting FGMs. Characterisation of the FGMs will include detailed description of microstructure, measurements of physical and mechanical properties and residual stresses. The modelling will be carried out at a design phase and for the material response to combined thermomechanical loading and extreme service conditions. Extensive use of multiscale approaches and numerical methods will be made. The project addresses the joint design of the FGM and the structural component it is intended for. Economical and ecological aspects of processing are included. Risks aspects of material non-performance will be tackled, too. MATRANS has mobilized a critical mass of interdisciplinary expertise and highly specialized equipment. The consortium includes leading groups from materials science, physics, chemistry, mechanical engineering and computer science. The industry and SME involvement in the project is substantial. As the exploitation measures, the industrial partners will define business plans and start pilot cases during the project, followed by upscaling activities after the project end.'

Introduzione (Teaser)

Scientists are developing materials combining ceramics and metals for high-performance and cost-effective aerospace and automobile parts. Such applications have never before been explored for the target applications considered in Matrans. Most people are familiar by now with composites, materials made of two or more individual materials and building on the strengths of each. Most of these materials look much the same no matter where one might take out a slice. Each of the materials might be visible but they tend to form the same matrix and filler composition throughout.

Descrizione progetto (Article)

In contrast, a functionally graded material (FGM) is a composite designed such that the composition varies (it is graded) throughout the volume in a way that adds functionality (hence, functionally). For example, a designer might strive for strength at one edge of a material gradually changing toward malleability at the other edge.

A European consortium is seeking to exploit novel metal-ceramic FGMs with EU funding of the 'Micro and nanocrystalline functionally graded materials for transport applications' (Matrans) project. Scientists are developing FGMs targeted for use in exhaust and propulsion systems, power transmissions and braking systems. Use of FGMs in these components is expected to provide significant performance enhancements compared to conventional materials.

Matrans is focused on two broad groups of ceramic-based (aluminium oxide (Al2O3)) FGMs, the first being ceramics-copper/copper alloys and the second ceramics-intermetallics (nickel aluminide (NiAl)). The former are geared toward thrusters (low content of Al2O3) and brake disks (high content of Al2O3) and the latter for valves. To date, the aforementioned materials have not been used in the specific applications.

The scope of the project includes the preparation of the starting materials (powders, cast foils and preforms), the processes applied to achieve the resulting FGMs and processing to produce the final part. The first two years have focused on the starting materials and processing of the composite layers for the FGMs, including characterisation of properties and microstructure as well as modelling work. To date, scientists have produced demonstrators made of FGMs for all three applications.

matrans has delivered new design concepts for aerospace and automotive components based on metal-ceramic FGMs. Enhanced performance and durability will contribute to longer part lifetime with lower costs.