Obiettivo
Precursor materials:
SiO2 and ZrO2 precursor materials were successfully developed to meet the specific needs for the process and the application. The development of suitable Al2O3 precursors for application on cemented carbides was not successful. The Ni/ZrO2 precursor for making electrically conductive layers was not laser-sinterable. An Ag-based precursor material proved to be a suitable alternative.
Ink-jetting:
Several of the SiO2 and ZrO2 precursor materials were successfully formulated into ink-jet inks suitable for printing on non-porous substrates. Concept inks with limited pot-life were made for the Al2O3 and Ni/ZrO2 sols. The print heads were modified to handle the aqueous inks developed in the project. The print head was adapted to print smaller droplets for fine line (60µm) applications. Lines and areas (2D) could be applied on steel and fused silica substrates using the inks developed. An electronic tool to run the OEM print-heads was developed and is now a commercially available product.
Sintering:
Laser-heating processes, specific for each substrate, were developed to sinter the precursor layers. Laser-sintering was successful for all precursors on fused silica (except the Ni/ZrO2). Several ZrO2 precursors could be laser-sintered on steel. Sintering of the Al2O3 precursors on cemented carbides was not successful. An analytical temperature model for laser heating was developed.
Equipment:
A demonstrator was built to run the Acerlink process on pilot scale. Accurate printing is possible, but integration of the other technologies was not yet achieved.
Applications:
Friction-reducing layers could be made by the Acerlink process on steel substrates. Well-conducting lines and areas could be made by laser heating. Multi-layer structures and composites could be made by laser-heating precursor layers made by spin-coating. Suitable ZrO2 layers with a refractive index of over 2 were made for pigment applications. It was also proven that the ZrO2 layers had suitable dielectric properties for applications in electronic compounds and circuits.
The multi-colour capability of ink-jet technology and the stereostiction process were not explored. Shaping of 3D bodies and the manufacturing of pigments were not studied.
1) Industrial companies manufacturing complex millimeter
sized ceramic mass products, typically made from plates
or bars containing many products suffer the problems of
the complexity and inflexibility of the batch oriented
processes. The separation of ceramic microparts causes up
to 30% waste of material. Ceramic products seriously
deform during sintering. Ceramic foils cannot be made in
layers below 5 mm thick but much thinner layers are
wanted.
2) In the coating industry the usual CVD process for wear
resistant layers is very time consuming and cannot be
applied locally.
The new technology inkjet prints a sol of nanosized
particles and directly dnes and laser sinters the
pattern. It is able to produce composite ceramic/ metal/
glass products with arbitrate patterns (also
3dimensional) directly sintered at low bulk temperatures
and without the need for subtractive shaping, trimming or
product separation afterwards. This is repeated many
times very fast in multilayers. The new technology is
called 'stereostiction'. Due to the additive nature of
the new technology and the flexibility of both inkjet and
laser technology the main benefits are:
* Reduction of manufacturing costs by up to 5 X reduction
of number of processing steps
* Full software control allows mass production with batch
size of 1 piece
* Additive processes produce no waste material for
product separation, giving up to 30% material cost
reduction and environmental load.
* Minimumlayerthickness
* Printing speed is at least 5 cm2/sec; the aim is 50 pm
line width and 5 1mm landing accuracy.
The first objective is 2 D local patterning of wear
resistant layers on various materials. The second
objective is 2 D patterning and composite generation
using the 'multicolor' capability of inkjet technology
using colloidal sols of different materials made via the
sol gel route instead of colored inks. The third
objective is 3 D shaping with ready sintered ceramics in
multi pass with a sliced CAD design where patterns are
stacked The fourth objective is reduction of costs and
environmental impact by the additive nature of the
technology and by the use of waterbased matrices instead
of organic solvents.
The consortium has strong complementary expertise's and
comprises two industrial users of the new technology and
know how: Philips for high tech electronic products and
Sandvik for high quality cutting tools. All partners are
developers/ suppliers: Merck introduce their expertise
for practical industrialization, Pelikan bring their ink
expertise, MIT bring inkjet system expertise, FHG ISC
bring sol gel expertise, Philips bring laser technology,
Sandvik bring wear resistance expertise and RuG bring
interface and microstructure expertise. Pelikan and MIT
are SMEs. A prototype system with an inkjet printer and a
laser system able to show the technology will be built.
High production speed is attainable by multiple high
speed nozzles. Laser sintered mono and multilayers will
be produced by dip and spin coating early in the project
to investigate the sintering process. The industrial
partners are responsible for process development together
with FHG ISC (solgel formulation) and Groningen
University (metal ceramic interfacing). Pelikan will
formulate the base sols to a printable liquid and act as
the industrial supplier while MIT will develop the
printing heads and build the prototype system with the
purpose to market the system. Philips will develop the
embedded laser technology.
The new technology can offer product design freedom in
ceramics, glass and even metals formerly impossible. In
principle also UV curing plastic monomers could be
processed using a UV laser (stereolithography with
inkjet).
Campo scientifico (EuroSciVoc)
CORDIS classifica i progetti con EuroSciVoc, una tassonomia multilingue dei campi scientifici, attraverso un processo semi-automatico basato su tecniche NLP. Cfr.: Il Vocabolario Scientifico Europeo.
CORDIS classifica i progetti con EuroSciVoc, una tassonomia multilingue dei campi scientifici, attraverso un processo semi-automatico basato su tecniche NLP. Cfr.: Il Vocabolario Scientifico Europeo.
- ingegneria e tecnologia ingegneria dei materiali compositi
- ingegneria e tecnologia ingegneria dei materiali rivestimenti e pellicole
- ingegneria e tecnologia ingegneria dei materiali solidi amorfi
- ingegneria e tecnologia ingegneria dei materiali ceramica
- scienze naturali scienze fisiche ottica fisica dei laser
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Parole chiave
Parole chiave del progetto, indicate dal coordinatore del progetto. Da non confondere con la tassonomia EuroSciVoc (campo scientifico).
Parole chiave del progetto, indicate dal coordinatore del progetto. Da non confondere con la tassonomia EuroSciVoc (campo scientifico).
Programma(i)
Programmi di finanziamento pluriennali che definiscono le priorità dell’UE in materia di ricerca e innovazione.
Programmi di finanziamento pluriennali che definiscono le priorità dell’UE in materia di ricerca e innovazione.
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Meccanismo di finanziamento
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Meccanismo di finanziamento (o «Tipo di azione») all’interno di un programma con caratteristiche comuni. Specifica: l’ambito di ciò che viene finanziato; il tasso di rimborso; i criteri di valutazione specifici per qualificarsi per il finanziamento; l’uso di forme semplificate di costi come gli importi forfettari.
Coordinatore
5600 MD Eindhoven
Paesi Bassi
I costi totali sostenuti dall’organizzazione per partecipare al progetto, compresi i costi diretti e indiretti. Questo importo è un sottoinsieme del bilancio complessivo del progetto.