5 Werkstofftechnik
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Organisationseinheit der BAM
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Lightweighting as a cross-cutting technology contributes significantly to achieve the European Green Deal goals. Based on, but not limited to, advanced materials and production technologies, the demand for natural resources and CO2 emmissions are reduced by lightweighting during production, as well as use phase. Therefore, lightweighting is a crucial transformation technology assisting in decoupling economic growth from resource consumption. In this manner, lightweighting contributes significantly as a key technology of relevance for many industrial sectors such as energy, mobility, and infrastructure, towards resource efficiency, climate action and economic strength, as well as a resilient Europe. To strengthen international partnerships, addressing global issues of today at the edge of science with high performance lightweight material based on carbon fibers, an overview about the BAM expertise in carbon fiber reinforced materials is given.
Knowledge representation in the materials science and engineering (MSE) domain is a vast and multi-faceted challenge: Overlap, ambiguity, and inconsistency in terminology are common. Invariant and variant knowledge are difficult to align cross-domain. Generic top-level semantic terminology often is too abstract, while MSE domain terminology often is too specific.
In this poster presentation, an approach how to maintain a comprehensive and intuitive MSE-centric terminology composing a mid-level ontology–the PMD core ontology (PMDco)–via MSE community-based curation procedures is shown.
The PMDco is designed in direct support of the FAIR principles to address immediate needs of the global experts community and their requirements. The illustrated findings show how the PMDco bridges semantic gaps between high-level, MSE-specific, and other science domain semantics, how the PMDco lowers development and integration thresholds, and how to fuel it from real-world data sources ranging from manually conducted experiments and simulations as well as continuously automated industrial applications.
Introduction
Lithium-ion batteries (LIBs) are one key technology to overcome the climate crisis and energy transition challenges. Demands of electric vehicles on higher capacity and power drives research on innovative cathode and anode materials. These high energy-density LIBs are operated at higher voltages, leading to increased electrolyte decay and the current collectors' degradation. Even though this fundamental corrosion process significantly affects battery performance, insufficient research is being done on the aluminum current collector. Fast and convenient analytical methods are needed for monitoring the aging processes in LIBs.
Methods
In this work glow-discharge optical emission spectrometry (GD-OES) was used for depth profile analysis of aged cathode material. The measurements were performed in pulsed radio frequency mode. Under soft and controlled plasma conditions, high-resolution local determination (in depth) of the elemental composition is possible. Scanning electron microscopy (SEM) combined with a focused ion beam (FIB) cutting and energy dispersive X-ray spectroscopy (EDX) was used to confirm GD-OES results and obtain additional information on elemental distribution.
Results
The aging of coin cells manufactured with different cathode materials (LCO, LMO, NMC111, NMC424, NMC532, NMC622, and NMC811) was studied. GD-OES depth profiling of new and aged cathode materials was performed. Quantitative analysis was possible through calibration with synthetic standards and correction by sputter rate. Different amounts of aluminum deposit on the cathode surface were found for different materials. The deposit has its origin in the corrosion of the aluminum current collector. The results are compatible with results from FIB-EDX. However, GD-OES is a faster and less laborious analytical method. Therefore, it will accelerate research on corrosion processes in high energy-density batteries.
Innovative aspects
- Quantitative depth profiling of cathode material
-Monitoring of corrosion processes in high energy-density lithium-ion batteries
- Systematic investigation of the influence of different cathode materials
The high operating temperatures of radial compressor wheels in exhaust gas turbochargers lead to a change in the original microstructure of the heat-resistant aluminum alloy EN AW-2618A (overaging). This is caused by thermal loads that are close to the age hardening temperature and can even exceed it for a short time. The aging mechanisms have been investigated together with low cycle fatigue (LCF), thermomechanical fatigue (TMF) and creep up to max. 190 °C in previous research projects. The be-havior of the alloy under high cycle fatigue (HCF) and the influence of load spectra have hardly been investigated. Since the operating temperatures of centrifugal compressors are expected to increase in the future, this research project investigated the HCF behavior at 230 °C, a test temperature significantly higher than the age hardening temperature. The objectives of the project were to establish a suitable experimental database, to understand the relevant microstructural processes, and to further develop and adapt suitable models and evaluation methods.
In addition to a basic characterization of the HCF behavior in the initial condition T61, the experimental investigation program included targeted mechanical tests to isolate the influencing factors of mean stress (𝑅=−1, 𝑅=0.1), material overaging (T61, 10 h/230 °C, 1000 h/230 °C), test temperature (20 °C, 230 °C), test frequency (0.2 Hz, 20 Hz) as well as variable amplitudes. On this basis, the models and evaluation methods developed in the previous projects were adapted and further developed to reflect thermal and mechanical loads in the lifetime assessment.
The high operating temperatures of radial compressor wheels in exhaust gas turbochargers lead to abchange in the original microstructure of the heat-resistant aluminum alloy EN AW-2618A (overaging). This is caused by thermal loads that are close to the age hardening temperature and can even exceed it for a short time. The aging mechanisms have been investigated together with low cycle fatigue (LCF), thermomechanical fatigue (TMF) and creep up to max. 190 °C in previous research projects. The behavior of the alloy under high cycle fatigue (HCF) and the influence of load spectra have hardly been investigated. Since the operating temperatures of centrifugal compressors are expected to increase in the future, this research project investigated the HCF behavior at 230 °C, a test temperature significantly higher than the age hardening temperature. The objectives of the project were to establish a suitable experimental database, to understand the relevant microstructural processes, and to further develop and adapt suitable models and evaluation methods. In addition to a basic characterization of the HCF behavior in the initial condition T61, the experimental investigation program included targeted mechanical tests to isolate the influencing factors of mean stress (𝑅 = −1, 𝑅 = 0.1), material overaging (T61, 10 h/230 °C, 1000 h/230 °C), test temperature (20 °C, 230 °C), test frequency (0.2 Hz, 20 Hz) as well as variable amplitudes. On this basis, the models and evaluation methods developed in the previous projects were adapted and further developed to reflect thermal and mechanical loads in the lifetime assessment.
Iron aluminides, already reported in the late 19th century, did not cease to attract the interest of scientists and engineers ever since. Besides good oxidation resistance, low density and resource availability, potentials for hightemperature strengths that compete with high-alloy steels were unlocked by low alloy contents. Still, research on alloy design continues, as alloying usually comes at the price of brittleness in low-temperature regimes. A potential candidate is the quinary Fe–Al–Mo–Ti–B system which is strengthened by solid solution and eutectic borides. It was shown to have good strength and outstanding creep resistance under compressive loading up to elevated temperatures. Although the individual effect of alloy additions is well understood in iron aluminides, little is known about the combined effects of alloying concentrations on microstructure, phase stability and mechanical properties. Therefore a systematic study of two Ti-doped near-Fe3Al alloys with varying contents of Mo (2–4 at.%) and B (0.5–1 at.%) was conducted. In total eight different alloys were fabricated by investment casting into ceramic shell molds. Alloys were characterized and compared by grain size, phase transitions, microstructure evolution as well as elemental compositions and volume fractions of phases. For mechanical characterization, macrohardness and microhardness tests as well as tensile tests at ambient and high tempera tures were conducted. Independent of alloy additions, alloys with 24–25 at.% Al exhibit superior proof strength due to a higher matrix hardness. Decreasing B content generally decreases strength by lower secondary phase fractions which contribute via particle hardening. Reducing Mo content decreases both the solute concentration in the matrix and secondary phase fractions. Surprisingly, strength is similar or even superior to alloys with higher Mo content. Strength relations are discussed with a focus on solid-solution hardening theory and other competing strengthening mechanisms.
Knowledge representation in the materials science and engineering (MSE) domain is a vast and multi-faceted challenge: Overlap, ambiguity, and inconsistency in terminology are common. Invariant and variant knowledge are difficult to align cross-domain. Generic top-level semantic terminology often is too abstract, while MSE domain terminology often is too specific.
The PMDco is designed in direct support of the FAIR principles to address immediate needs of the global experts community and their requirements. The illustrated findings show how the PMDco bridges semantic gaps between high-level, MSE-specific, and other science domain semantics, how the PMDco lowers development and integration thresholds, and how to fuel it from real-world data sources ranging from manually conducted experiments and simulations as well as continuously automated industrial applications.
Additive Manufacturing for dental restorations by layerwise slurry deposition (LSD-print) technology
(2023)
The growing market of custom-made dental restorations offers a major potential for an application of ceramic additive manufacturing (AM).
The possibility to individualize patient specific design and to establish new efficient workflows, from model generation to manufacturing, can be fully exploited by AM technologies. However, for mass customization to be truly envisioned, ceramic AM needs to achieve a level of maturity, aesthetic quality, and productivity comparable to established manufacturing processes.
In this presentation, the potential of the “layerwise slurry deposition” LSD-print technology for dental applications will be explored. It has been shown in the past years that the LSD-print can be applied to advanced ceramic materials such as alumina and silicon-infiltrated silicon carbide. For these materials, the LSD-print technology combines the high-speed printing of binder jetting with the possibility of producing a variety of high-quality ceramics.
The current development deals with the challenges of applying this technology to a feldspar dental material, comparing the quality of AM restorations with the equivalent material for an established CAD/CAM workflow.
Preliminary results not only indicate that the AM material produced by LSD-print can be competitive in terms of mechanical properties, but also that aesthetically satisfactory restorations can be manufactured for veneers, inlays and onlays as well as single unit fixed dental prostheses (FDPs).
The presentation focuses on the material and technological challenges alongside the process chain, from the printing process, to debinding, firing and finishing the restorations.
The presentation gives an overview of two slurry-based additive manufacturing (AM) technologies specifically developed for advanced ceramic materials.
The “Layerwise Slurry Deposition” (LSD-print) is a modification of Binder Jetting making use of a ceramic slurry instead of a dry powder as a feedstock. In this process, a slurry is deposited layer-by-layer by means of a doctor blade and dried to achieve a highly packed powder layer, which is then printed by jetting a binder. The LSD-print technology combines the high-speed printing of binder jetting with the possibility of producing a variety of high-quality ceramics with properties comparable to those achieved by traditional processing.
The Laser Induced Slip casting (LIS) technology follows a novel working principle by locally drying and selectively consolidating layer-by-layer a ceramic green body in a vat of slurry, using a laser as energy source. LIS combines elements of Vat Photopolymerization with the use of water-based feedstocks containing a minimal amount of organic additives. The resulting technology can be directly integrated into a traditional ceramic process chain by manufacturing green bodies that are sintered without the need of a dedicated debinding.
Both technologies offer high flexibility in the ceramic feedstock used, especially concerning material and particle size. Advantages and disadvantages are briefly described to outline the specific features of LSD-print and LIS depending on the targeted application.
A giant Zn segregation transition is revealed using CALPHAD-integrated density-based modeling of segregation into Fe grain boundaries (GBs). The results show that above a threshold of only a few atomic percent Zn in the alloy, a substantial amount of up to 60 at.% Zn can segregate to the GB. We found that the amount of segregation abruptly increases with decreasing temperature, while the Zn content in the alloy required for triggering the segregation transition decreases. Direct evidence of the Zn segregation transition is obtained using high-resolution scanning transmission electron microscopy. Base on the model, we trace the origin of the segregation transition back to the low cohesive energy of Zn and a miscibility gap in Fe-Zn GB, arising from the magnetic ordering effect, which is confirmed by ab-initio calculations. We also show that the massive Zn segregation resulting from the segregation transition greatly assists with liquid wetting and reduces the work of separation along the GB. The current predictions suggest that control over Zn segregation, by both alloy design and optimizing the galvanization and welding processes, may offer preventive strategies against liquid metal embrittlement.