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Grosman F.,Silesian University of Technology | Madej L.,AGH University of Science and Technology | Ziolkiewicz S.,Instytut Obrobki Plastycznej | Nowak J.,AGH University of Science and Technology
Journal of Materials Processing Technology | Year: 2012

The main subject of the present work is to present the new and innovative manufacturing technology based on the incremental forming approach. The idea is to develop a deformation process that is strictly based on small incremental deformations realized by a series of thin anvils. To realise this idea in practise this idea, a proper geometry of the upper die has to be designed. In the present work it is a set of several rolls (pressure rollers) that moves down towards a series of small anvils and performs rotational movement at the same time. As a result, the pressure is not transferred by the upper die directly to the material. The pressure is transferred to the sample through the series of thin anvils. To incrementally transfer the desired final shape to the forging a series of anvils with various lengths has to be used. Due to the complexity and novelty of the proposed approach, a set of questions has to addressed. These are related to appropriate depth of anvil indentation, material flow under a single anvil, material interaction with anvils and interaction between subsequent anvils. This basic research is done in the present work with the use of simple laboratory tests. Then detailed experimental analysis of material flow in the developed new process is presented. At this stage of the research the prototype of the proposed device is created on the basis of the orbital Marciniak forging press (Marciniak, 1970). All the obtained results are presented, and conclusions related to the effectiveness of the process are highlighted. The experimental part of the research is also supported by numerical analysis. The commercial finite element (FE) Forge2005 software was used in the present work to evaluate the forging process parameters and analyze the character of material deformation. The obtained numerical results are compared with the experimental analysis performed on the developed prototype press. © 2012 Elsevier B.V. All rights reserved.


Grant
Agency: Cordis | Branch: FP7 | Program: CP-TP | Phase: NMP.2013.4.0-3 | Award Amount: 5.35M | Year: 2013

The vision of PilotManu is the upscale of the current mechanical alloying technological facility into a powder manufacturing pilot line by further developing existing IPR-covered results owned by the SMEs in the consortium related to mechanical alloying technology and to innovative powder materials for different applications. The baseline technology that will be upscaled from a technological facility status into pilot scale, is the High Energy Ball Milling machine, able to deliver innovative materials for new product lines developed by SMEs and industrial partnership that will lead the technological upscale. The project will demonstrate the technological and economical viability of the pilot line by implementing advanced materials into coatings, abrasive tool and additive manufacturing applications. Additional application sectors will be represented in the business cases by analyzing the cost/benefits of using the following new materials: Mg hydrides for hydrogen storage, thermoelectrics for energy harvesting, flame retardant textile and polymer nanocomposite for rapid prototyping. The potential impact brought by the new HEBM pilot production will be transversal also in all those technological sectors demanding high performance and outstanding material properties not achievable by conventional products. These huge un-exploited knowledge reservoir related to materials produced via HEBM or Mechanical Alloying will be unlocked by the Pilot Manu production system able to bring these results into the market.


Patent
Instytut Obrobki Plastycznej | Date: 2014-11-03

A method for the manufacturing of metallic matrix composites through plastic working is disclosed. In the method, the plastic working charge is in the form of wires, tape or tapes or foil, which is the first component being covered with the second component or components with granulation less than 100 m, after which they are connected by reciprocal surface contact, forming weaved bundles, and then the connected elements which form the charge material advantageously undergo initial rolling or drawing and in all cases the principal process, which is extrusion performed on a rolling mill with circumferential grooves, where between rollers a closing matrix is placed, rotating in reverse to its axis by an angle of 20 advantageously 12, with a frequency up to 50 Hz, advantageously 15 Hz.


Grant
Agency: Cordis | Branch: FP7 | Program: CP-FP | Phase: HEALTH.2013.1.3-2 | Award Amount: 7.20M | Year: 2013

Europe is confronted by a demographic challenge as a decreasing work force has to support an increasing elderly population. The economic risk implied by this burden could be addressed by efforts to achieve an increase in Healthy Life Years. One key element would be to ensure unrestricted mobility for especially the elderly, allowing them to stay at work for longer. Irreversible joint deterioration often requires a joint replacement. Implantation of artificial joints is one of the most successful orthopaedic interventions. However, an increasing number of patients receive revision surgery with these 10 % of these contract an infection and 50 % develop an adverse immune reaction (AIR) to conventional implant material. At the moment the reasons for the development of AIR are inadequately understood. Our proposal contains innovative solutions concerning this problem. A predictive approach using biomarkers will identify patients with risk to develop AIR. These patients will receive hypoallergenic endoprostheses, avoiding AIR to conventional material. Novel hypoallergenic material combinations will be developed in the frame of this consortium by material scientists and implant manufacturer. Via immunological, microbiological and biocompatibility testing the development and production process will be improved constantly. The matching of implant material with the allergenic background of patients will avoid complicated and cost-intensive reverse reactions and is a step towards personalised medicine. A further approach is to achieve a better understanding of mechanisms of AIR, and its faster and easier diagnosis using sensitive diagnostic biomarkers for an accurate differentiation from low-grade infection. Additionally, mathematical modelling of results from different methods will show us the gene regulatory network that leads to an amplification of the adverse immune response triggered by prosthetic implants and will develop predictive models of AIR process.


Grant
Agency: Cordis | Branch: FP7 | Program: BSG-SME | Phase: SME-2013-1 | Award Amount: 1.05M | Year: 2013

Since traditional lubricants fail when friction is combined with high temperature, it is either impossible or impractical to use these materials in many industrial applications. The need for improved lubricating technologies is critical when trying to solve tribological problems concerning dry friction or boundary lubrication under high temperatures. The goal of the HIGRAPH project is to provide participating SMEs and the machinery industry with a novel technology for manufacturing sliding and rotating components that enhances dry-friction performance under high temperatures, increases durability, and extends the service lifetime of the part. It will be reached by encapsulation of High Temperature Solid-lubricant (HTSL) particles (such as WS2, WSe2, h-BN, Al-Mg-Si, BaF2, CaF2, etc.) into a micro-sized reservoirs. These reservoirs maintain the mechanical integrity of the matrix, and can slowly release the HTSL particles onto the sliding interface. As a result, both friction and wear are reduced. Friction forces and surface reactions generate a lubricious transfer film at the tribological contact, where a lubricating film with the required chemistry and structure is formed. This allows to retain the HTSL particles inside a hard, thermo- and oxidation-resistant matrix, and ensures operational integrity at extremely high temperatures. While maintaining low friction at high temperatures is important, wear resistance requires an additional blend of hardness and fracture toughness. Toughness of the developed coating will be enhanced through stress minimization, crack deflection, and ductility. The coating will be applied using powder metallurgy and sprayed coating modification methods to satisfy industrial requirements concerning coating thickness and allowable wear tolerance, which vary from 10500m.

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