Boost for materials research

Researchers could submit project proposals together with companies, which contribute fifty percent of the project costs in cash. Both theoretical and experimental research projects have been awarded funding. All of the projects are fundamental in nature and also have a clear link to an application. A list of all projects awarded funding can be found at the end of this press release. 

About the HTM calls
Within the Top Sector High Tech Systems and Materials (HTSM), the FOM Foundation and Technology Foundation STW together with the Materials innovation institute (M2i) have organised a series of High Tech Materials calls. Since spring 2013 calls have been organised twice per year, with FOM or STW acting as the lead party. The aim of the HTM calls is to give a boost to scientific materials research – aimed at industrial application – in the Netherlands.

Projects awarded funding, with main applicants and participating companies (all part of the M2i consortium) and research institutions:

Prof. A.H. van den Boogaard (University of Twente) – Tata Steel, Fontijne Grotnes
Material property and process scatter in forming of high strength steels (Differentiation through tailored scatter)
With Advanced High Strength Steels (AHSS), the weight of cars can be reduced, which improves the energy efficiency and reduces CO₂ emissions. But AHSS are more critical in forming than commonly used mild steels and consequently the forming processes are closer to the limit. Then material property and process scatter often leads to failures in production. Process designers therefore need to employ mathematical optimisation to achieve robust metal-forming processes, taking the process and material scatter into account. In this project, a useable model to quantify scatter for real materials in forming and spring back will be developed, with all process aspects included. Tata Steel will use this model to help their customers achieve robust production of AHSS and thus fulfil the fuel consumption and emission requirements.

Dr. M.J.M. Hermans (Delft University of Technology) –Tata Steel, DAF
Towards intrinsically safe microstructures in resistant spot welded advanced and ultra high strength automotive steels
The potential for weight reduction, ease of manufacturing and improved crashworthiness makes advanced high strength steels (AHSS) and ultra high strength steels (UHSS) attractive for automotive applications. The commercial application of these materials requires that premature weld failure, due to adverse microstructure development during resistance spot welding, can be avoided. In this project, we will determine the underlying physics of key aspects of microstructural evolution. A successful outcome of this project will enable a faster development of new, weldable AHSS/UHSS by early identification of possible welding problems and solutions.

Prof. C.R. Kleijn (Delft University of Technology) – Tata Steel
Modelling of vapour flows for design optimisation of a novel Physical Vapour Deposition equipment - How do vapour jets interact when supersonically expanding into vacuum?
Our research aims to address the question of how multi-species vapour jets supersonically expand into vacuum, and how their vapours condense due to expansion of the jet and its impingement on a cold surface, where a solid film condenses. A particular topic of interest is the interaction between multiple, closely spaced vapour jets. The interest for this topic stems from its application in physical vapour deposition (PVD) of thin solid coatings from vapour jets impinging on solid surfaces, particularly in the continuous coating of surfaces moving at high velocities, such as anti-corrosion coating of steel plates. Solving this problem will lead to large energy and materials savings in the steel industry.

Dr. J.M.C. Mol (Delft University of Technology) – Tata Steel, Max-Planck-Institut für Eisenforschung, Vrije Universiteit Brussel
The effects of mobility of water and charge carriers at polymer-metal interfaces on long-term stability of a polymer-metal hybrid system
Galvanised steel surfaces are often coated with an organic layer to increase the corrosion resistance. Due to the presence of defects, organic coatings are permeable to water, oxygen and/or corrosive ions leading to cathodic delamination at the polymer-metal interface. In this project, we will try to improve the long-term stability of polymer-metal hybrid materials by controlling the mobility of water and charge carriers along the polymer-metal interface. The knowledge obtained will be directly applicable by Tata Steel in various production routes adding value to the end products.

Dr. J.M.C. Mol (Delft University of Technology) – Tata Steel, AkzoNobel, Vrije Universiteit Brussel
Chromate-free inhibitor technology for protection of coated galvanised steel
All branded organic coated galvanised steel products must be chromate-free by the end of 2017. In order to implement novel inhibitor technologies for coated galvanised steel products in the market, basic knowledge regarding inhibitor interaction with the organic coating, influencing in-coating migration and leaching, and metal substrate as well as the protection level is needed. In this study, both the inhibitor-coating and inhibitor-metal interactions will be studied and optimised for the hybrid polymer-metal substrates used by Tata Steel.

Prof. I.M. Richardson (Delft University of Technology) – Allseas
A new simulation based approach to welding process optimisation
Hybrid laser-arc welding offers potential advantages for faster weld completion, particularly in relation to full penetration positional welds in pipeline materials where the number of weld passes can be reduced. Welding process optimisation, however, remains problematic because of the large number of operating variables and the lack of understanding of parameter interdependencies. We will develop a simulation that provides insight into melt pool stability based on the oscillatory stability of a melt pool with two free surfaces supported on the sides by solid material. The melt pool will be free to oscillate as a function of orientation, to simulate the effect of positional orientation. Results should significantly decrease the time required for optimisation of welding process parameters. 

Dr. M.B. de Rooij (University of Twente) – DAF, SKF
Lubrication and accelerated testing of highly dynamic cam follower contacts
To reduce fuel consumption in reciprocating internal combustion engines, the automotive industry is always searching for ways to reduce internal frictional losses. At the same time, the same power output should be generated out of a smaller engine, which means higher loads on mechanical components. A critical component in an engine is the cam follower unit, which is a lubricated contact experiencing highly dynamic operational conditions in terms of load and velocity, coming from the camshaft that drives it. Lubrication is of significant importance in the prevention of cam failure caused by wear. The main aim of our research is to establish the lubrication conditions in a highly dynamic contact by means of numerical modelling and experimental investigation. SKF and DAF will use this knowledge to critically evaluate accelerated lifetime tests and provide input for the optimisation of the tribological contact.