METAL MATRIX NANO-COMPOSITE COATINGS UTILIZATION AS ALTERNATIVE TO HARD CHROMIUM

Project Information

MOZART

Grant agreement ID: 101058450

DOI

10.3030/101058450

Project closed

EC signature date 24 May 2022

Start date 1 June 2022

End date 31 May 2026

Funded under

• Digital, Industry and Space

Total cost

€ 4 660 537,50

EU contribution

€ 4 660 536,00

Coordinated by

POLITECNICO DI MILANO
Italy

Periodic Reporting for period 2 - MOZART (METAL MATRIX NANO-COMPOSITE COATINGS UTILIZATION AS ALTERNATIVE TO HARD CHROMIUM)

Reporting period: 2023-12-01 to 2024-11-30

Summary of the context and overall objectives of the project

In an era increasingly attuned to environmental considerations, MOZART project emerges as a pivotal initiative poised to revolutionize the domain of ultra-hard surfaces. Chromium (Cr6+), historically acclaimed for its unparalleled hardness, now faces heightened scrutiny owing to its environmental toxicity. MOZART project, boldly endeavors to introduce a sustainable alternative to Cr6+ through the application of nanocomposite coatings. Cr6+, despite its hardness, is not immune to inherent drawbacks. Acknowledging the imperative to address environmental concerns associated with chromium, MOZART project is dedicated to formulating an ecologically sound substitute via the development of nanocomposite coatings. These coatings, distinguished by properties such as corrosion resistance and high hardness attributed to a layer of nanoparticles, possess the unique advantage of seamless integration into existing manufacturing infrastructure, thereby ensuring a cost-effective solution. The project endeavors to showcase the viability of these coatings on a pilot scale through the implementation of AI-driven simulations and advanced electroplating techniques.

The principal aim of MOZART project is to propose sustainable coating solutions that supplant Cr6+ in specific applications, particularly those necessitating high wear and corrosion resistance. Noteworthy is the adaptability of nanocomposite coatings to existing plating shops, requiring only minimal modifications for the safe integration of nanoparticles. The project's multidisciplinary approach, validated through prior endeavors at the laboratory scale, is strategically designed to elevate the technology readiness level (TRL) to 5. This involves demonstrating the technology in pilot-scale applications and real-world demonstrators across manufacturing, automotive, and machinery industries.

MOZART project meticulously delineates a pathway to impact through the incorporation of a Safe & Sustainable by Design strategy. Drawing on in-silico methods, including Artificial Intelligence and Simulations, in tandem with online monitoring technologies, chemical functionalization of nanoparticles, and advanced electroplating techniques, the project aspires to attain high-quality, durable composite coatings. The convergence of these technologies is anticipated to propel the nano-composite coatings to the desired level of technological maturity.

Foreseen impacts of MOZART project are expansive, offering a sustainable substitute to Cr6+ in critical applications. The introduction of novel nano-composite coatings is poised not only to alleviate environmental concerns but also to instigate a paradigm shift in industries reliant on ultra-hard surfaces. Anticipated impacts encompass a significant reduction in environmental toxicity, cost-effective adoption by manufacturers leveraging existing infrastructure, and a fundamental shift toward sustainable practices within manufacturing, automotive, and machinery sectors.

As MOZART project unfolds, it lays the foundation for a narrative of transformative significance in the realm of coating technologies. With a steadfast commitment to sustainability, cutting-edge methodologies, and a meticulously outlined pathway to impact, MOZART endeavors to leave an enduring imprint, contributing to a future where ultra-hard surfaces coexist harmoniously with the environment.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

From the administrative perspective, by M30 (Nov 2024), 13 Deliverables (3 updates) and 9 Milestones have been achieved. Four CM, 2 Review, 2 pre-Review, and numerous group meetings have been successfully organized. Regular calls between partners ensured progress in tasks and deliverables.
Main achievements and activities:
- Specifications & Requirements: Chemicals, methods, and end-user specifications documented in D2.1 as a baseline, with updates planned as the project evolves.
- MOZART SSbD Strategy: Fully adopted by partners, actively integrated into workflows.
- Simulation Activities: Progress in T3.2–T3.4 includes hydrodynamic conditions in composite electrolyte, CAD of jig/tooling systems, and BoM optimization via virtual twin simulation. Updates to follow in M36.
- Validation of SiC NP gravitational impact in Elsyca’s simulations (MS4).
- Plating Line Upgrades: SSbD principles applied to upgraded plating lines at Cnano and PoliMi, NP-liquid batch preparation at MBN, U/S integration, and online NP measurement via BRAVE’s OF2i system. Preliminary Ni-release tests on coatings (boric acid-free electrolytes) by UoB demonstrate feasibility.
- Boric Acid-Free Electrolytes: Formulations by Tecnochimica and CNano enable Ni coatings with properties equal to or better than those from traditional baths. (MS3)
- Tribological Characterization: FALEX assessed samples from PoliMi and CNano, confirming boric acid-free coatings match traditional electrolyte performance.
- Lab-scale Ni/SiC nanocomposite coatings (1006 ± 105 HV) achieved via pulse current plating on REACH-compliant electrolytes using functionalized SiC NPs from MBN. (MS5)
- LCA/LCC Analysis: Initial sustainability assessment covering technologies, use cases, methodology, and Goal/Scope definition.
- Hybrid Dataset Release: AIMEN published an AI training dataset on Zenodo: https://doi.org/10.5281/zenodo.10551522
- Ni/Gr Coatings: CNano developed a REACH-compliant bath for Ni/Gr nanocomposite coatings, achieving CoF = 0.10 (200 cycles) and <0.15 (1000 cycles), verified by FALEX.
- OF2i Monitoring System: Installed at CNano’s premises with BRAVE’s support. Documentation (photos/videos) to feature in the Technical Report, deliverables, and project dissemination materials.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

At these 30M, it is imperative to highlight the significant strides of MOZART project:
- Remarkable progress in developing sustainable alternatives to hard chromium through nanocomposite coatings.
- Sustainable coating solutions not only address the environmental hazards posed by hard chromium but also offer a safer alternative for both industrial workers and end-users.