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Development of engineering surface coatings obtained by advanced, cost effective and environmentally friendly technologies

Objective


Technical achievements in task 1
TASK 1 was a real and pure research task with a very high innovative content, separated in 3 main subtasks. The main achievements to date are:
i. A new industrial technology and methodology for the spraying of synchroniser rings using unconventional 'semi-axial' torch and, a precious know-how concerning the design/assemblage of components to produce a full axial torch prototype, an open road for the usage of plasma sprayed coating for synchroniser rings (instead of the old and unique one process in this field: the wire metallisation).
ii. A new plasma spray powder production process (SHS) where our feasibility study permitted us to demonstrate that this new powder technology can be easily applied in the field of plasma spraying with considerable perspective and promises at both the technical and costs levels.
iii.An assessment of both APS and RPS technologies for the spraying of MMC materials.

TASK 2 aim's was the production of high performant multilayer systems by PVD and CVD, using new engineered facilities. Technical achievements are the production of extremely hard nitride multilayer systems and oxide multilayer systems by PVD and several ultra hard multilayer systems (phases of TiN, TiAlN, TiB2, TiCN) by PACVD.

TASK 3

i.Development and Optimization of high performance steels for application of hot-forming.
ii.Development of a suitable technology to produce, via plasma spray, near-net-shape shells for composite dies
iii.Preparation and coating of industrials parts, using the outcomes of task 1 and task 2, these parts have been tested in task 4.

TASK 4 main achievements are:

i.The constitution of a consequent databases concerning the behaviour of engineered Plasma Spray coatings applied on synchronizer rings.
ii.A much better understandings of the problematic of the synchronizer rings that make PRAXAIR deciding to build-up an own testing bench

i. Development of high performance steels and combined CVD treatments that lead to increase the life duration of industrial hot forming dies. Assessment of in-service wear performance.
ii. A set of experimental data, results and in service wear performance of new PS, PVD and CVD coatings for truck chassis stamping and synchronizer rings.
In the present project, our objective is to develop cost effective methods in t he field of wear resistant coatings. Our approach will be to examine a broad ra nge of techniques with the aim of optimising the process parameters in view of a selected number of industrially relevant applications. Coating technology is progressing at a steady rate with continuous significant improvements in the co atings performance. In general, however, performance alone is not sufficient to determine the success of a new technology, and it must be balanced against cos t and environmental impact. Up to recent times, the least expensive coating tec hnology (electrochemical chromium plating) was also the most polluting one. How ever, if it will be possible to lower the cost/performance ratio of technologie s based on gas phase processes (CVD or PVD) or of plasma spray, it will also be possible to completely replace the still widely used polluting electrochemical methods with more environmentally friendly methods. Our R&D effort will be foc used on a number of key projects which will permit to obtain significant steps forwards in some of the commercially relevant methods of coating production. Th ese will be, mainly: - A European high deposition rate axial plasma gun . - Ne w thermal spray powders using recycled materials and simplex powders - Low cos t reactive plasma spray - New coatings - New techniques for coating productio n - Advanced modelling of the coating wear process After 3 years of R&D effor t in these areas we believe that we will have built up a significantly improved set of techniques and developed a strategy for an application-oriented approac h to process optimisation that can be used not only for the coatings examined h ere, but in general for all systems where there exist parts undergoing mechanic al wear. Our project satisfies the basic criterion of subsidiarity since the or ganisation of such a consortium would be difficult to obtain on the basis of na tional research programs. The added value of carrying out this project at the E uropean level lies in the capability of pooling resources - not just financial but also human in terms of knowledge and commitment. In particular, the partner s involved in the program belong to 5 different EU countries and they will shar e their expertise and equipment in these key technological areas. The technolog ical advances generated by the present project will be of great value in enhanc ing the competitivity of the European industry in the worldwide market.

Funding Scheme

CSC - Cost-sharing contracts

Coordinator

PRAXAIR SURFACE TECHNOLOGIES SPA
Address
Via Fleming 3
28100 Novara
Italy

Participants (9)

Acom Srl
Italy
Address
Strada Busano
10083 Favria
CONSEJO SUPERIOR DE INVESTIGACIONES CIENTIFICAS
Spain
Address
Campus Universitat Autonoma De Barcelona
08193 Bellaterra
Commission of the European Communities
Netherlands
Address
3,Westerduinweg
1755 ZG Petten
IMPERIAL COLLEGE OF SCIENCE, TECHNOLOGY AND MEDICINE
United Kingdom
Address
Exhibition Road
SW7 2BX London
INSTM - CONSORZIO INTERUNIVERSITARIO NAZIONALE PER LA SCIENZA E TECNOLOGIA DEI MATERIALI
Italy
Address
Via Maragliano 77
50144 Firenze
Iveco Fiat SpA
Italy
Address
59,Lungo Stura Lazio
10156 Torino
National University of Ireland, Galway
Ireland
Address

90 Galway
RUEBIG GMBH & CO KG
Austria
Address
Schafwiesenstrasse 56
4600 Wels
TEER COATINGS LTD
United Kingdom
Address
Hartlebury 290, Trading Estate, Hartlebury
DY10 4JB Kidderminster,hartlebury