Wiener Neustadt, Austria
Wiener Neustadt, Austria

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Agency: European Commission | Branch: FP7 | Program: JTI-CS | Phase: JTI-CS-2012-2-ECO-01-054 | Award Amount: 150.00K | Year: 2013

Corrosion of Al has to be counteracted by first anodizing the Al parts and applying further protective coatings. Anodized aluminium is normally further processed with a sealing as a final step after anodizing. A hot water sealing process is one of the widely used methods. However in order to close (seal) the pores in the aluminium oxide anodized layer for corrosion protection a process involving boiling water containing chromate is still commonly used. Cr(VI)-based sealing solutions have been employed for several decades, but remain one of the most effective and commonly-used methods to improve corrosion resistance of anodized aluminium. Alternative sealing methods have also been proposed for example with Ni(II), Co(II), Ni(II) and Co(II), rare earth salts alkali metal fluorides, alkanolamine salts of phosphonic acids, Cr(III), fatty acids, silicates, etc. Kendig and Buchheit indicate that 45 of the 92 naturally occurring elements have been considered as replacements for Cr(VI) in conversion coatings on aluminium. In general these approaches have not been as successful as the Cr(VI) sealing. Also it should be noted that Ni(II), Co(II) and fluorides are not without health implications, whereas most organic molecules would be expected to have limited lifetimes under the extreme conditions (UV radiation, low pressure, large temperature range) experience by commercial aircraft during operation. Therefore, of the previously identified approaches Cr(III)-containing or silicate-forming sealing solutions are preferred options. Encouraging results were obtained with deposition of films of CeO2.2 H2O on aluminium alloys in a few minutes at room temperature with or without catalyst, though the performances still do not equal those of CCC. Detailed investigations and characterization of the obtained will be performed. The optimized sealing and pre-treatments process will be applied to a flat test panel of 384 x 742 mm.

Agency: European Commission | Branch: FP7 | Program: JTI-CS | Phase: JTI-CS-2012-3-ECO-01-058 | Award Amount: 100.00K | Year: 2013

The proposed project will focus on the validation of a TSAA process, including pre- and post-treatment, which is defined by the topic manager, and its implementation in industrial scale. An existing industrial plant, which will be selected by the topic manager, will be benchmarked with respect to the number and dimensioning of the components of the plant and its periphery with respect to the technical requirements for the process. The process itself will be performed in laboratory- and pilot scale to verify the reproducibility of the process for given aluminium alloy(s) and to characterize and quantify the properties of the surface of specimens after each step of the TSAA process. Failure mode analyses, such as FTA (failure tree analysis), DRBFM (Design review based on failure mode) and FEMS (Failure modes and effects analysis) will be performed. Knowledge-based analysis of the process and the relevant parameters, such as temperature and filtration, as well as the aforementioned failure mode analysis, will lead to the definition of process sheets and risk assessment plan. Environmental analysis of the process will consider chemicals used also with respect to REACh compliance -, exhaust fumes (especially in the working area), waste and waste water output. As far as possible, recycling routs for process waters and chemical components will be analysed and suggested. Risk analysis will also include possible health risks in the working area, which can origin by incorrect use of chemicals or waste. The results of the analysis of environmental and health risks will be included into the process sheets and risk assessment plan. Data and process-relevant knowledge gained during the aforementioned analysis steps will finally lead to elaboration of a manufacturing plan and compilation of a Process procedures and standard manual.

Agency: European Commission | Branch: FP7 | Program: BSG-SME | Phase: SME-1 | Award Amount: 1.49M | Year: 2009

Hydraulic power transmission with oil as power transmission fluid is widely applied in industrial applications. The main consumer of hydraulic fluids are heavy duty hydraulic machines such surface and underground mining equipment, drilling rigs and earth-moving machines. Petroleum-based hydraulic fluids and lubricants are persistent and toxic. They need to be disposed at the end of life in order to minimize the dispersion in the environment, and the are carcinogen and have resulted in almost 10,000 workers developing malignant tumours, resulting in more than 5,600 reported deaths/year in the EU. Additionally the use of oil-based hydraulic machines poses severe fire and safety concern in harsh industrial environment (i.e. high temperature). The inevitable trends in the construction industry and legislation show very clearly that the oil in the hydraulics should be replaced with less pollutant media. Biodegradable synthetic oils show lower performance, poor lubrication, higher costs, greater wear, seal compatibility problems, and long-term stability concerns. Substitution of oil by water is the best solution for an environmental, safety, health and cost perspective. However in the high-pressure fluid applications, the requirements for the substrate/coating systems are extremely severe, because wear resistance, friction and corrosion aspects must be addressed. Nowadays no application of water hydraulics in the machines for construction and mining, which represents the biggest market for hydraulic components and the largest consumers of oil, exist. HYDRO-COAT project is aimed at developing the knowledge and the technology to produce a new range of environmental friendly machines for construction using water as hydraulic fluid, addressing the technical barriers imposed by the use of water instead of oil. This objective will be reach by integration innovative coating solutions with optimal design of hydraulic components for use with high-pressure water.

Agency: European Commission | Branch: FP7 | Program: CP | Phase: ICT-2011.9.1 | Award Amount: 3.62M | Year: 2012

The MANAQA project is a multidisciplinary approach that combines innovative technologies emerging from different fields including nanotechnology, biochemistry, and nanorobotics. The strategy that will be exploited is based on a recently developed 5-DOF magnetic manipulation system combined with an atomic force microscope (AFM) system and functionalized magnetic nanowires. The fusion of these technologies has the potential to revolutionize many aspects of single-molecule manipulation and measurement. Information related to the structure and physical properties of macromolecules (i.e., proteins, polynucleotides) will be obtained. In a typical experiment, a molecule will be regiospecifically attached between a magnetic nanowire and the tip of an AFM cantilever. The extremely small footprint of the magnetic nanowire and the accuracy of a five degree-of-freedom magnetic manipulation system will allow high-resolution and stable force control on the molecule. The mechanical response of the molecule will be monitored using the AFM cantilever. Moreover, the system will be capable of measuring the electrical parameters of the nanowire-molecule hybrid. The success of this proposal will lead to long time-scale, low drift experiments that will provide invaluable insights on mechanisms governing conformational changes in single macromolecules by elucidating protein folding/unfolding/refolding trajectories at a low-force regime. This will contribute to the long-term vision of MANAQA of establishing a biomolecular measurement platform with extended capabilities. MANAQA opens new avenues in disciplines such as biochemistry, pharmacy, and biomedicine. The development of new miniaturized electronic devices within the scope of MANAQA project with single chemical entities integrated as their components will revolutionize the field of Information and Communication Technologies (ICT).

Agency: European Commission | Branch: FP7 | Program: BSG-SME | Phase: SME-2013-1 | Award Amount: 1.40M | Year: 2013

Currently, display industries, LCD and OLED displays manufacturing is based on Indium-Tin Oxide (ITO) Transparent Conducting Films (TCF). Nevertheless, Indium metal is a very scarce material and its worldwide resources are becoming increasingly limited. Thus, the prices of produced displays based on ITO will inevitably rise day by day if no alternative material is developed to replace it. Moreover, ITO films have limitations in flexibility and this fact excludes them from application in the production of new-generation displays, such as electronic books and flexible displays. The guiding principle of NanoDiGree is to manufacture, through economical viable production methods, competitive high quality transparent conducting films in order to replace ITO. This projected solution will be based on the production of conductive/transparent inks containing Cu nanowires which will be fabricated via advanced pulse electrodeposition (PED) methods. The Cu nanowires will be electro deposited into anodised aluminium oxide (AAO) nanoporous-templates by utilizing pulse current electrodeposition. The produced nanowires will be dispersed in green solvent mixture in order to develop the printing inks for the afterwards production of the films. Finally, Roll-to-Roll printing will be used in order to apply thin flexible conductive-transparent films on suitable polymer substrates that will be used as the flexible devices. The goal of the NanoDiGree proposal is to intercept the trend of integration of all supply chain manufacturer of displays in Asia by producing high added value component in Europe. The successful outcome of this project will have a significant impact in European competitiveness within the market of TCF. Indeed, the impact is intended to be significant, considering that the alternative TCFs address the need of constantly growing market sectors, which nowadays widely use ITO. These are the electronic displays as well as the solar panels manufacturers.

Hansal W.E.G.,Happy Plating GmbH | Sandulache G.,Happy Plating GmbH | Mann R.,Happy Plating GmbH | Leisner P.,Jönköping University College
Electrochimica Acta | Year: 2013

This paper describes the effect of modulated bipolar current (pulse reverse plating) on the incorporation of micron and submicron sized SiC particles within an electrodeposited Ni-P alloy matrix (dispersion coating). Based on electrochemical measurements, a pulse plating process has been defined and the effects of pulse parameters (type of current, frequency of current pulses and current density), the electrolyte composition and the size of the silicon carbide on the particles incorporation rate, phosphorus co-deposition rate, surface morphology, structure, micro hardness and wear resistance of the deposits has been investigated. The experimental results show that the phosphorus co-deposition and the particles incorporation rate decrease applying higher current density. The reduction of particle size decreases the co-deposition content of the particles within the coating. Application of pulsed current leads to a more compact composite coating, significantly improving the hardness and the tribological behaviour of the Ni/SiC deposits, mainly at higher frequency of the applied current pulses. DC and bipolar pulses generate unfavourable higher co-deposition rate of phosphorus, hence a loss in hardness has been observed. Tailored shift of the properties and alloy composition during the deposition process can be achieved by change of matrix properties via alternation of the pulse sequences. © 2013 Published by Elsevier Ltd.

Mann R.,Happy Plating GmbH | Hansal S.,Happy Plating GmbH | Hansal W.E.G.,Happy Plating GmbH
Transactions of the Institute of Metal Finishing | Year: 2016

One remaining problem of thicker PEO based topcoats on light metal substrates is the enhanced porosity with increasing layer thickness. While modern deposition techniques such as pulsed anodisation counteract this phenomenon, a simple current signal based approach cannot completely eliminate this problem. In the process described in this paper the pulse anodised PEO layers are modified by the incorporation of functional nanoparticles and the effects of such embedded nanoparticles on the resulting microstructure of the layer are studied. The examination of the layer properties was performed using scanning electron microscopy, electrochemical techniques and X-ray diffraction methods. The dependency of corrosion resistance on the presence of nanoparticles in the layer as well as the alloy composition of the substrate and the applied current signal is shown. © 2016 Institute of Materials Finishing.

After the great success of the previous European Pulse Plating Seminars the 7th such conference was held in Vienna, once again, on 3rd and 4th March 2016, marking the 10 year anniversary since the first Pulse Plating Seminar was held in Vienna in 2006. For the second time, the Pulse Plating conference was combined with the annual scientific meeting EAST Forum of the European Academy for Surface Technology (EAST). Owing to this combination, the event could be enlarged to a 2-day conference, providing 26 presentations to the interested audience. The conference and the parallel exhibition focussed on both the scientific and the industrial approach of modern electrochemical surface technology, with a special focus on the pulse plating technique on the second day. Seventy-five participants coming from 16 different countries helped maintain an intensive and very productive discussion on the topic that will be continued in 2018 at the 8th European Pulse Plating Seminar in Vienna. The next EAST Forum will be held in 2017. © 2016 Institute of Materials Finishing.

Hansal W.E.G.,Happy Plating GmbH
Galvanotechnik | Year: 2013

Pulse plating has for many years been a prominent topic for discussion and indeed could be said to have assumed almost mystical properties. There have been countless publications based on laboratory work, mostly reporting superb results. By contrast, very little has been reported on large-scale production plating operations using this technology. Almost all Metal Finishing businesses and production plants to have adopted this technology (which has in most cases proved successful) have chosen not to announce the fact. As a result, the question is asked again and again whether pulse plating is in fact suited for use on a large industrial scale and whether there might not be insuperable scale-up problems associated with this.

Mann R.,Happy Plating GmbH | Hansal W.E.G.,Happy Plating GmbH | Hansal S.,Happy Plating GmbH
Transactions of the Institute of Metal Finishing | Year: 2014

In this paper, the effects of different current pulse parameters on the resulting PEO layers are described. The properties of the layers were assessed optically, with a scanning electron microscope, and the corrosion resistance has been measured. It is shown that the polarity and the frequency of the applied current has a high influence on the properties of the resulting layers. Unipolar pulses with low frequencies produce rougher layers with reduced corrosion protection. Different additives were added to the electrolyte in order to improve corrosion resistance of the resulting layers. Some of the additives, especially if based on tungstate and molybdate resulted in a colouring effect of the layer. This colouring effect is most pronounced when low frequencies and unipolar pulses are used. Higher frequencies and bipolar pulses create smoother and denser layers with higher corrosion resistance. The highest corrosion resistance was obtained by combining addition of tungstate and high frequency bipolar pulses. © 2014 Institute of Materials Finishing. Published by Maney on behalf of the Institute.

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