Advanced Materials Processing  
Processing dynamics and optical materials
Nanocomposites fabrication and coatings
Electromagnetic processing of functional materials

Nanocomposites fabrication and coatings

Modern nanocomposite materials are based on the production, surface modification, mixing and shaping of materials. The group focuses on the synthesis of the nanopowders and participates in the consecutive steps of producing nanocomposites.
Optically functional nanocomposite materials will be a novel direction of this group, applying technologies and methodologies acquired from other materials fields. These fields are non-oxide semiconductor or hard material nanoparticles production and its inclusion as components into novel materials. Depending on the composite type, i.e. cermet, or cerpolym, metpolym the putting in shape might be different and will be adapted.
Another activity is the production of coatings e.g. by thermal spraying, inspiring more fundamental studies of the influence of multiple components on the interaction/interplay of properties of “composite” coatings.

Plasma synthesis of nanoparticles
146 kB
Inductively coupled plasma apparatus developed at Empa for the thermal plasma processing of nanopowders.

Synthesis of nanopowders is carried out with an inductively coupled plasma setup. Dedicated to research activities it is equipped with numerous view ports for process observation, monitoring, and in-situ characterization. The nanoparticles plasma synthesis is based on rapid condensation, also called quenching, of a supersaturated gas phase. The quenching dynamics influence the nanoparticles properties such as size, size distribution and eventually the final chemical composition. The control and understanding of this condensation is of prime importance for guaranteeing the quality of the processed nanopowders.

The high temperatures (10000 K) and moderate velocities (100-200 ms-1) observed in radio frequency (RF) inductively coupled plasmas are particularly suitable for the evaporation of solid precursors. The starting material in our case is thus typically microscale powders that are mostly commercially available and easy to handle in a safe way. Furthermore, the process is performed under a controlled atmosphere (reducing, oxidizing or inert) allowing then the production of a large variety of nanoparticles.

In parallel to scientific and technological investigations, the Health, Safety and Environment (HSE) issues have been evaluated and best practice guidelines have been developed regarding production and manipulation of nanopowders. Particular attention has been also paid to the design of a special filtration unit.

Nanostructured materials and nanoparticulate strengthened composites
31 kB
Hardness of pure aluminium reinforced with 1vol% SiC nanoparticles as a function of the milling energy developed in a planetary ball mill (PM400, Retsch). J. Alloys and Compounds, in press.
New industry materials are needed to meet a wide range of energy efficient applications with increased specific stiffness, specific strength, damage tolerance, ductility, creep and reliability in extreme environments.
Adding nanoparticles into metals results in composite materials with drastically improved properties, unachievable by using conventional materials and chemicals. Besides the intrinsic properties of filler and matrix material, control of the degree of dispersion of the nanofiller in the matrix is a key issue towards functional nanocomposite materials. The research in his field is targeted on the development of processing parameters for uniform dispersion of plasma synthesized carbides and nitrides or functionalized carbon nanotubes in various metal matrices. The degree of dispersion, size, concentration, and interfacial properties are related to the functional properties and the performance of the nanocomposite material for specific applications. For example, the hardness and the tensile strength of Al-based matrix composites reinforced with various nanoparticulate materials could be improved by at least a factor of 4 to 5. 
 Additionally, also the consolidation of purely nanoparticulate materials to bulk shape as promising candidates for high performance materials is under investigation.
Thermal spraying
123 kB
Spraying chamber for VPS and APS coating, with control unit (outside) and robot (inside chamber).
Coatings are applied to surfaces in order in enhance the functionality compared to the substrate material. The coatings are used to improve wear resistance, for corrosion protection, as barriers against thermal damage, for connectivity and much more. Methods such as flame spraying (FS) and plasma spraying in vacuum (VPS) or atmosphere (APS) are attractive methods for the production of such coatings as they are fast techniques that allow the processing of a wide range of materials, from polymers to high temperature melting metals and ceramics.
We support industry as well as research activities in the fields of materials selection and the development of new coating solutions. Examples of previous work are e.g. thermal barrier coatings on pistons (e.g. Al2O3), resistive heating coatings for LHC getter pumps, coatings for Fuel Cell applications (e.g. ZrO2), porous metal coatings (e.g. Ti), coatings for implants (e.g. Hydroxyapatite) and wear resistant coatings (e.g. hard metals) for turbine blades.
Affiliation

Laboratory for Advanced Materials Processing
Empa - Materials Science & Technology
Feuerwerkstrasse 39
CH-3602 Thun

Tel.: +41 58 765 1133
Fax.: +41 33 228 44 90

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