ASTERIXE ProjectBrochure V2 - KIT - IHM · A European STREP project supported through the Sixth...
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A European STREP project supported through the Sixth Framework Programme for Research and Technological Development ASTERIXE - Development of advanced surface technology for extended resistance in extreme environment - ASTERIXE is aiming at developing innovative combined surface treatments promoting a technological breakthrough for high performances in the field of Environmental Barrier Coatings (EBC’s). These coatings play a key role in high temperature (>600°C), highly corrosive environments and high mechanical (and cumulative) stress conditions. The goal of the project is to open new routes of surface engineering by combining coating deposition and advanced post treatment technologies by pulsed e-beam (PEB). The understanding of the phenomena interacting on the coating composition and structure will be developed throughout the project with the creation and optimization of a model predicting the coating composition and structure after post treatment. The coatings will be deposited by a range of different processes, electrochemical, spray or vapour deposition, the process choice being mainly dependent on the elemental composition needed to fulfill the application requirements. The pulsed e-beam treatment will be used to give the coating its final structure and morphology. This may for some applications involve interface melting promoting coating to base material alloying. As a result, the coating process will be optimized by using the results of the predicting model, and by testing new combinations with respect to the chemical composition (new chemical systems, hybrid layers, self-repairing coatings…). The efficiency of the PEB post treatment will be compared with the results obtained by laser post treatment (one of the reference methods). The laser post processing will be also coupled with the electrodeposition process to propose a “low cost” alternative. Potential impact The global market for the coating industry reaches 25 billion Euro per year in Europe with an anti-wear and anticorrosion coating market of 20 billion Euro per year, and is expected to grow in the near future. Active R&D efforts in the field of surface treatment have enabled today new coatings, new functionalities and new processes to be achieved and that could meet during the early next century some untapped innovation needs of new large breakthrough markets. The new breakthrough markets targeted by the project are the following: Industries Breakthrough markets AEROSPACE MMC - composite parts, intelligent structural, improved bond coat’s, new TBCs... AUTOMOTIVE Cylinder bores, piston rings, exhaust pipes, friction materials ... CONSUMER DURABLES Heating resistances, EMC, protective coatings... ENERGY PRODUCTION Improved overlay and bond coat’s, new TBCs… ELECTRICAL & ELECTRONICS EMC, resistors and circuitry... MECHANICAL COMPONENTS Pumps, compressors, valves, hydraulic cylinders, rolling elements/bearings, sleeves... Innovative outputs In every application case, an improvement in component lifetime, reliability and systems MTBF (Mean Time Between Failure) is the first expected benefit. One of the main goals is also the deposition of thinner coatings with equivalent performance allowing both weight saving and strategic material economy. Integrating surface engineering by multifunctional coatings into the overall components design open new fields of application reflecting enhanced performance levels. As an example, more effective bond coatings will be possible by application of the new combined coating processes. In the field of advanced ceramics coating, changing the surface composition by this new combined coating technology can also improve the performance of the coating. Moreover, it is expected that thermal barriers properties can be associated with high corrosion protection in new coating systems. The last objective of the project, which presents a very high degree of innovation, is the application of the new combined coating process for the creation of a self diagnostic coating system. This “sensor” coating will allow the understanding of the TBC behavior, through monitoring temperature and also optimizing its thermal properties. Project deliverables include: A new concept of interface treatment leading to enhanced coating adhesion strength by simultaneously melting of the coating and the substrate surface A new process of extremely fast surface quenching from the melt leading to values of density and toughness of the surface layer close to the theoretical “bulk” values without affecting the substrate material A new route to obtain still unavailable chemical compositions by combining multilayer coating and surface alloying A new route for a self diagnostic coating or sensor coating EADS CCR KSB Aktiengesellschaft
Transcript of ASTERIXE ProjectBrochure V2 - KIT - IHM · A European STREP project supported through the Sixth...
A European STREP project supported through the Sixth Framework Programme for Research and Technological Development
ASTERIXE - Development of advanced surface technology for extended resistance in extreme environment - ASTERIXE is aiming at developing innovative combined surface treatments promoting a technological breakthrough for high performances in the field of Environmental Barrier Coatings (EBC’s). These coatings play a key role in high temperature (>600°C), highly corrosive environments and high mechanical (and cumulative) stress conditions. The goal of the project is to open new routes of surface engineering by combining coating deposition and advanced post treatment technologies by pulsed e-beam (PEB). The understanding of the phenomena interacting on the coating composition and structure will be developed throughout the project with the creation and optimization of a model predicting the coating composition and structure after post treatment.
The coatings will be deposited by a range of different processes, electrochemical, spray or vapour deposition, the process choice being mainly dependent on the elemental composition needed to fulfill the application requirements. The pulsed e-beam treatment will be used to give the coating its final structure and morphology. This may for some applications involve interface melting promoting coating to base material alloying. As a result, the coating process will be optimized by using the results of the predicting model, and by testing new combinations with respect to the chemical composition (new chemical systems, hybrid layers, self-repairing coatings…). The efficiency of the PEB post treatment will be compared with the results obtained by laser post treatment (one of the reference methods). The laser post processing will be also coupled with the electrodeposition process to propose a “low cost” alternative.
Potential impact The global market for the coating industry reaches 25 billion Euro per year in Europe with an anti-wear and anticorrosion coating market of 20 billion Euro per year, and is expected to grow in the near future. Active R&D efforts in the field of surface treatment have enabled today new coatings, new functionalities and new processes to be achieved and that could meet during the early next century some untapped innovation needs of new large breakthrough markets. The new breakthrough markets targeted by the project are the following: Industries Breakthrough markets
AEROSPACE MMC - composite parts, intelligent structural, improved bond coat’s, new TBCs...
AUTOMOTIVE Cylinder bores, piston rings, exhaust pipes, friction materials ...
CONSUMER DURABLES Heating resistances, EMC, protective coatings...
ENERGY PRODUCTION Improved overlay and bond coat’s, new TBCs…
ELECTRICAL & ELECTRONICS EMC, resistors and circuitry...
MECHANICAL COMPONENTS Pumps, compressors, valves, hydraulic cylinders, rolling elements/bearings, sleeves...
Innovative outputs In every application case, an improvement in component lifetime, reliability and systems MTBF (Mean Time Between Failure) is the first expected benefit. One of the main goals is also the deposition of thinner coatings with equivalent performance allowing both weight saving and strategic material economy. Integrating surface engineering by multifunctional coatings into the overall components design open new fields of application reflecting enhanced performance levels. As an example, more effective bond coatings will be possible by application of the new combined coating processes. In the field of advanced ceramics coating, changing the surface composition by this new combined coating technology can also improve the performance of the coating. Moreover, it is expected that thermal barriers properties can be associated with high corrosion protection in new coating systems. The last objective of the project, which presents a very high degree of innovation, is the application of the new combined coating process for the creation of a self diagnostic coating system. This “sensor” coating will allow the understanding of the TBC behavior, through monitoring temperature and also optimizing its thermal properties.
Project deliverables include: A new concept of interface treatment leading to enhanced coating
adhesion strength by simultaneously melting of the coating and thesubstrate surface
A new process of extremely fast surface quenching from the melt leadingto values of density and toughness of the surface layer close to thetheoretical “bulk” values without affecting the substrate material
A new route to obtain still unavailable chemical compositions bycombining multilayer coating and surface alloying
A new route for a self diagnostic coating or sensor coating
EADS CCR KSB Aktiengesellschaft
A European STREP project supported through the Sixth Framework Programme for Research and Technological Development
The Project Team The ASTERIXE consortium is composed of 11 partners with complementary expertise, coming from five European countries. There is a core of five research partners, three industrial technology suppliers, two industrial end-users and a consultancy company : CEA: Deposition processes, like PVD, CVD and plasma enhanced
CVD, of multifunctional coatings - Implementation of the processes and understanding of material behaviour
FZK: Liquid metal and high temperature corrosion pulsed power electron beam physics (design and diagnostic) and the modification of materials applying e-beams and materials research - Development and understanding of the surface alloying process. Design of an integrated industrial facility
STS: Monitoring technology of thermal barrier coating (TBC) systems - Development of the technology
Cranfield: Advanced coatings for high temperature service and monitoring technology - Creation of sensor coatings. Deposition of TBCs. Cyclic oxidation testing. Understanding of materials behaviour
INSTM: Implementation and understanding of electrodeposition process with ionic liquids
CTC: Implementation of PVD process Turbocoating: Thermal spray coatings of components for
industrial gas turbines and aero engines manufacturing - Implementation of the process
ARES: Application of laser technology as post treatment EADS: Aerospace and defence applications - Industrial
requirements and validation of the combined process KSB: Pumps, valves and associated systems for building
services, industry and process engineering, water and waste water, energy and mining - Industrial requirements and validation of the combined process
ALMA: Administrative and financial management of the project
Development of advanced surface technology for extended resistance in extreme environment ASTERIXE Contract number : NMP3-CT-2003-505953 Start date : 01/01/2004 End date : 31/12/2006 (Duration : 36 months) Project cost : 2 768 847 € EC Funding : 1 638 667 €
Project Coordinator Dr Pierre JULIET, CEA [email protected]
Commissariat à l'Energie Atomique - CEA Grenoble (F) www.cea.fr
Forschungszentrum Karlsruhe GmbH - FZK Eggenstein-Leopoldshafen (D) www.fzk.de
Southside Thermal Sciences Ltd - STS London (UK) www.stscience.com/ Cranfield University Cranfield (UK) www.cranfield.ac.uk Consorzio Interuniversitario Di Scienza e Technologia Dei Materiali - INSTM Firenze (I) www.instm.it
Centrum Technologii Cienkowarstwowych SP.zO.O - CTC Opole (PL) www.ctc.vipnet.pl/ Turbocoating Rubbiano di Solignano (I) www.turbocoating.com/
ARES Laser Saint Ouen l'Aumône (F) www.ares-laser.fr/ European Aeronautic Defence and Space Company - EADS Suresnes (F) www.eads.com KSB Aktiengesellschaft Pegnitz (D) www.ksb.com ALMA Consulting Group Lyon (F) www.almacg.com, www.prodige.com
ACKNOWLEDGEMENT
Supported by the European Commission through the SixthFramework Programme for Research and TechnologicalDevelopment, the ASTERIXE project addresses the Key Action3.4.2.2 Technologies associated with the production,transformation and processing of knowledge-basedmultifunctional materials, and biomaterials of the “NMP”Thematic Priority.
