enea - uttmatf faenza technical unit on material...

ENEA - UTTMATF Faenza Technical Unit on MATerial Tecnologies

1. R&D ON NEW MATERIALS AND TECHNOLOGIES

2. ENGINEERING AND QUALIFICATION

3. SERVICES

Faenza Research Laboratories

1. R&D on new materials and technologies

R&D lines

➮ ADAVANCED MATERIALS

➮ MANUFACTURING TECHNOLOGIES

ADAVANCED MATERIALS ➮ CERAMIC MATERIALS

MO

NO

LITH

IC

S

CO

MP

OS

ITES

OXIDES and

MIXED OXIDES

NON OXIDES

ZrO2, Al2O3, 3Al5O12, (YAG), Mullite, ZTA, SiO2, Y2O3, etc.

SiC, ZrC, SiC/AlN, AlN, Si3N4, MoSi2, Mo5Si3

FIBRE-REINFORCED

THICK COATINGS

Cf/C, SiCf/SiC, Basaltf/SiCO


ca. 290m

ca. 50m

Mullite + BSAS

Mullite

SiC

ca. 290m

ca. 50m

Mullite + BSAS

Mullite

SiC

Mullite, BSAS, Al2O3, SiC-MoSiO2, SiC, C

THIN FILMS

SiO2, Al2O3, TiO2, ZrO2, TCO (Transparent Conductive Oxide), SiC, C C

OA

TIN

GS

&

TH

IN

FILM

S

CO

ATIN

GS

&

TH

IN

FILM

S

THICK COATINGS

THIN FILMS

Ceramic modified polymeric coatings

Hybrid organic - inorganic (ORMOCER) In situ laser induced nanoparticles

SPECIAL ORGANIC FERTILIZERS

(from manure, waste, byproducts)


Organic fertilizers with slow release Nitrogen, Bating agents for leather production

BIO-REMEDIATION Tailored compost

ADAVANCED MATERIALS ➮ HYBRID MATERIALS

ADAVANCED MATERIALS ➮ BIOBASED MATERIALS

Uncoated steel

Coated steel

REC

YC

LIN

G P

ILO

T

AP

PLIC

ATIO

NS


ADAVANCED MATERIALS

STR

UC

TU

RA

L

MA

TER

IA

LS

FU

NC

TIO

NA

L

MA

TER

IA

LS

Thermal systems

Biomaterials

High efficiency devices

Functional thin films

Protective coatings

Transparent ceramics

Mechanical components

Heat exchangers, gas – turbine stator, engines, furnace lining

Orthopaedic prosthesis, dental devices

Seal rings, thread guides, brake discs, armour, cutting tools, bearings

Power lasers, optical windows, domes, jewellery

Corrosion/oxidation and wear resistant coatings

UV-Vis-NIR anti-reflective, IR-reflective, UV-Vis anti-reflective, photocatalytic hydrophobic/oleophobic films

OLED/OLET

Special organic fertilizers

Slow release nitrogen fertilizers

Electrical components

Electrical insulators


MANUFACTURING TECHNOLOGIES MONOLITHIC CERAMICS

FORMING MACHINING THERMAL TREATMENTS

• Cold isostatic pressing • Slip casting • Injection moulding

• Before and after sintering • Dewaxing • Sintering • Pressure sintering (hot press)


MANUFACTURING TECHNOLOGIES COMPOSITE CERAMICS

CVI/CVD process PIP process


MANUFACTURING TECHNOLOGIES COATINGS and THIN FILMS

• Sol-gel/slurry coating (dip, spin, spray)

• Chemical Vapour Deposition

• Pack cementation

• Electrophoretic deposition


MANUFACTURING TECHNOLOGIES POLYMERIC MATERIALS

RAPID PROTOTYPING

• X-ray diffraction (XRD)

• Thermoanalysis (TG, DTG, DTA up to 1500 °C)

• Optical and scanning electron microscopy

• Fluorescence spectrometer

• Epifluorescence microscopy

• UV - Vis spectrophotometer

MICROSTRUCTURAL, CHEMICAL AND PHYSICAL CHARACTERIZATION


2. Engineering and Qualification

Competences

• Standard thermomechanical tests on instrumented samples, data elaboration

and statistical analysis of results

• Design and setting up of standard and non-standard mechanical tests

• FEM (Finite Element Method) analysis

• Reliability analysis of components


Instruments

• Three machines for static and dynamics tests

up to 500 kN and 1500°C

• Ten machines for tensile creep tests up to

1000°C

• Three machines for flexure creep tests up to

1500°C

• Pressurization tests up to 200 bar.

• Fatigue tests based on rotational flexure

• Frequency analysis by resonance method

• Impact tests


Materials

• Polymeric composites (PMCs)

• Ceramic composites (CMCs)

• Metals

• Ceramic materials and refractories

• Construction materials

• Thermoplastics and thermosetting polymers

• Sandwich structures

Industrial solutions

ENERGY

Turbine blades

Combustion chambers

Refractory liners

Heat exchangers

• Leachable Ceramic Cores for DS- investment casting • SiC turbine blades • Ceramic protective coatings (EBC, TBC)

Materials and coatings for high temperature and corrosive environments (SiC based materials, self-healing ceramics, ceramic coatings)

Nuclear plants • SiC (monolithic and composite) and Cf/C for fuel claddings • SiC-SiC reactive brazing process with high temperature oxidation resistance • Creep tests in lead of ceramic coated metals

EFFICIENCY - SAVINGS


ENERGY

• Antireflective thin films • Al2O3 ring insulators

Solar plants

Thermo-photovoltaic plants

Oxide and non-oxide ceramic components

Transparent Conductive Oxide thin films DSSC

Wind plants • Nanostructured corrosion resistant thin films • Mechanical characterization of innovative materials for turbines

RENEWABLE

CONSTRUCTION

Fire resistant panels

Fibre reinforced inorganic composites

Easy to clean surfaces

Super–hydrophobic/oleophobic coatings for tiles, frames and windows

Uncoated steel

Coated steel


TRANSPORTS

• Intrusion tests on composite panels • Tests on custom - made components

Brake discs

Ceramic composites (Cf/C)

Light devices OLED (Organic Light-Emitting Diode)

Thermostructural components

Ceramic composites (basalt reinforced)

Racing car components

Satellites

• SiC mirrors • Ceramic windows optimized for extreme environments (YAG, AlON) • Reentry thermal protections (UHTC, Cf/C)

Structural components

• Ceramic composite (SiCf/SiC) Leading Edge and Trailing Edge • Ceramic protective coatings (EBC, TBC)

Engines

Mechanical characterization of CFRP composites

AUTOMOTIVE

AEROSPACE


MEDICINE

Orthopaedic and dental devices

Drug-dosimeter

Scalpels

Preliminary studies for prototypic ceramic devices

Zirconia acetabular cup, ZTA ankle prosthesis , ZTA endosseus implant, zirconia - ZTA dental crown

Prototypic ceramic scalpels (ZrO2)

MANUFACTURING

Glass industry • Corrosion and oxidation resistant ceramics for heat recovery • Thermo-mechanical characterization and molten salt corrosion tests

Plastic and FRP industry

• Ceramic additives for PE • Temperature resistant composites

Appliance industry • Transparent Conductive Oxide for oven doors • Photocatalytic coatings for water treatment


MECHANICAL INDUSTRY

Thermo-mechanical characterization, qualification and FEM analysis on materials and components

• Fatigue tests on gas springs

• Tensile tests and FEM analysis on steel sheets for cold drawing

• Fatigue tests on mold steels

• High temperature compression tests on custom - made components of packaging machine

• Mechanical characterization of brazing and welding of industrial components


ANTI - BALLISTIC

Protection systems • Ceramic windows (YAG)

• SiC and AlON based materials

• Thermo-mechanical characterization of aircraft materials and components

• Fibre reinforced composites

BIOECONOMY

Biobased materials Materials and technical products obtained from poultry dejection

Bioremediaton Innovative low impact bioREmediation technology to reduce Methane emissions and hazardous conditions (REM)

CURRENT projects - EUROPEAN

TITLE COORDINATOR DESCRIPTION FOUNDING

TYGRE ENEA UTT-NANO High added value materials from waste tyre gasification residues

European Union-FP7

RESEARCH PROJECTS

LIFE PROJECTS


ECOFATTING CNR- ICCOM

Environmentally friendly natural products instead of chloroparaffins in the fatting phase of the tanning cycle

European Union – LIFE10

PODEBA ENEA UTTMATF Use of poultry dejection in the bating phase in the tanning cycle

European Union – LIFE10

SOREME CNR- ICCOM Low cost sorbent for reducing mercury emissions

European Union – LIFE+ 11

RESAFE DICMA Sapienza University of Rome

Innovative fertilizer from urban waste, bio-char and farm residues as substitute of chemical fertilizers

CE - LIFE 12

CURRENT projects - ITALIAN


ECOAPPLIANCES INDESIT spa Development of IR reflective coatings

Industria 2015

PPIF CARNJ SOC. COOP. Materials and devices for monitoring (sensors for agroindustrial)

Industria 2015

ITALY 2020 CRF Thermostructural CFCCs for automotive

Cluster “Trasporti Italia 2020” MIUR

MITAI

Certimac

Development of technologies for local SME: low cost production of thermostructural CFCCs

FESR funds - Faenza Technopole

LAERTE (SAFE)

ENEA

Evaluation of certified systems for improving thermo hygrometric comfort of buildings by means of renewable energy and innovative materials

FESR funds – Bologna Technopole

CONCLUDED research projects


GENERATOR S.C.E. Srl

Study and characterization of innovative materials and development of nanostructured corrosion resistant thin films for wind power applications

Industria 2015

LAMP ENEA UTTMATF

Laser induced synthesis of polymeric nanocomposite materials and development of micro-patterned hybrid light emitting diodes (LED) and transistors (LET)

European Union - Objective ICT-2009.3.8

MAMAS Consortium TRE

Development and characterization of multifunctional panels for building protection (from fire, earthquakes and other incidental conditions) and energy saving

PNR - FAR

MITGEA CNR-IENI

Development and characterization of new materials for turbine engines (liners, refractories, coatings, superalloys) and for turbine blades production (ceramic cores)

PNR – FAR - FIRB

SEMPRE CETMA

Corrosion resistance study of refractories and metals in alkaly molten salts and in oxidation enviroments at high temperature for components in glass industry; characterization of wear resistance materials for glass waste recovery

PON 2007-2013 – PNR - FAR

3. Services

Faenza Research Laboratories offer an innovative, multidisciplinary and integrated

know-how in the field of the chemistry and material engineering:

• Engineerization and technological transfer of innovative processes to the

industries

• Thermomechanical testing of materials and components in different conditions

• Microstructural, chemical and physical characterization of ceramic materials,

composites, metals, organic-based materials (biomass and organic fertilizers)

• Studies aimed to the innovative application of the new materials

20 m20 m20 m

ENEA Companies and Consortia

Industrial certification and research laboratory

supplying an even wider range of qualification

services on building materials (e.g. CE marking,

thermal analyses)

• Energy Savings in buildings

• Energy Retrofit processes

• Smart buildings

• Innovative materials for building envelope

• Social Housing solutions and systems

• Mechanical, chemical, thermo-physical and durability evaluation and characterization of building materials

SKILLS AND MAIN TOPICS OF INTEREST

www.certimac.it

Consortium for development and application of innovative design techniques for

land and rail transport component production

Consorzio PROCOMP Sviluppo e applicazione di progettazione avanzata

per la realizzazione di componentistica per i trasporti

www.consorzio-procomp.it

ENEA Companies and Consortia

Contacts

Faenza Technical Unit on Material Technologies Head: Sergio Sangiorgi e-mail: [email protected] Address Via Ravegnana, 186 48018 - Faenza (RA) Tel. 0546 678540 Fax. 0546 678501 e-mail: [email protected]

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