success stories in the materials field · 2015-08-11 · 3 table of contents 4 purpose-designed...

Success stories in the materials field

A decade of EU-funded research

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Directorate-General for ResearchDirectorate G – Industrial technologiesUnit G3 ‘Value – added materials’E-mail: [email protected]: http://ec.europa.eu/research/industrial_technologies/

EUROPEAN COMMISSION

Directorate - General for Research, Industrial technologies2008 Unit G3 ‘Value – added materials’ EUR 23581 EN

Success stories in the materials fieldA decade of EU-funded research

M. Chamberlain and J.L. Vallés

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3

Table of contents

4 Purpose-designed materials key

to transformation of European industry

7 Success stories in FP5

8 One-step process to complex, high performance steel parts (2002-2006)

9 Nanocomposite ceramics make longer-lasting artificial joints (2001-2004)

10 Biotechnologically produced organic chemicals from biomass

offer new potentials (2003-2005)

11 Spinal inserts relieve lower back pain (2001-2005)

12 Enzyme-based sensors allow bio-process optimisation (2002-2006)

13 Single-crystal superalloys make aero-engines safer (2002-2007)

15 Success stories in FP6

16 Multifunctional nano-materials sourced from renewable cellulose (2004-2006)

17 Interactive materials beat bottlenecks to new pharmaceuticals (2004-2008)

18 Advanced surface technology makes turbines more efficient (2004-2006)

19 Bioartificial pancreas could end insulin injections for diabetics (2004-2006)

20 Nanostructured superconductors pave the way

to high temperature/high magnetic field applications (2005-2008)

21 Bioprocessing improves on natural materials (2004-2007)

22 Novel intermetallic alloys for ‘green’ applications (2004-2009)

23 Ligand bank speeds process development (2004-2006)

24 Hepatocyte constructs point the way to liver re-growth (2005-2008)

25 Magnetoelectric films promise power-saving electronic devices (2006-2009)

26 Polymer nanocomposites reduce power demand

for electrochromic eyewear (2004-2007)

27 Nanocrystalline Si films to cut cost of optoelectronics (2005-2008)

28 Water-borne adhesives eliminate solvent use (2004-2007)

29 Organics bring prospect of faster electro-optics (2004-2007)

30 Tailored molecules lay foundation for efficient nanodevice

production (2004-2007)

31 How clean are self-cleaning windows? (2004-2007)

32 ‘Smart’ packaging vital to a sustainable future (2004-2008)

4 S U C C E S S S TO R I E S I N T H E M AT E R I A L S F I E L D

Purpose-designed materials key to transformation

Mankind’s progress in using materials to improve the quality of life marks major milestones in the march of civilisation – from the stone age, through the bronze and iron ages, and on into the silicon age of nowadays. Cur-rent trends suggest that the next era could be identified as the age of nanotechnology.

At present, a great deal of the world’s manufacturing capacity is becoming concentrated in the lower-wage economies of the developing nations. Much of this pro-duction is currently underpinned by western technology; but there is evidence that – even in a globalised market-place – research and development also tend to migrate towards the centres of industrial activity. Capitalising on Europe’s innovative strengths to retain a mastery of materials is one key aspect of an effective response to this challenge: it is vital in enabling the EU to maintain lasting competitiveness and safeguard employment in the region.

European creativity initiated the industrial revolution of the 18th and 19th centuries, which saw rapid progress from a world dominated by manual labour to one driven by mechanical manufacturing and characterised by a prolif-eration of scientific discovery. This triggered a huge increase in the consumption of natural resources and energy, which has now reached a scale that most acknowledge will be unsustainable in the longer term. Today’s need is to har-ness technologies that will continue to meet growing human aspirations, while minimising the use of raw mate-rials, consuming less power, exploiting renewable assets, and minimising waste and environmental pollution.

In short, this requires a transformation from resource-inten-sive approaches towards a knowledge-based European society, capable of achieving sustainable development and growth. It implies a shift from quantity- to quality-based paradigms of production and consumption; from mass-produced single-use products to new concepts of higher-added-value, eco-efficient products, processes and services.

Drivers of innovation

Advanced materials with a high knowledge-content providing new functionalities, improved performance and greater versatility in application are critical drivers of innovation in virtually every sector – from transport and construction to energy, electronics and healthcare.

Research into such knowledge-based materials will not only contribute to the development of new markets and emerg-ing technologies, but also to increasing the competitiveness of traditionally less knowledge-intensive industries – textiles and clothing, for example – that are under particular threat from the lower-cost manufacturers.

Europe already has a powerful presence in materials science. Its universities and research centres are key play-ers; while industrial enterprises in areas such as chemicals, electronics, aeronautics and transport are also develop-ing fundamental knowledge that is helping to secure international leadership in several strategic domains.

Although newly emerging nanotechnologies are expect-ed to offer the greatest long-term prospect of radical innovation, they will certainly depend to a great extent on materials technologies. Meanwhile, the broader fields of materials research remain extremely important in the medium term. Breakthroughs will come not only from the new materials themselves, but also from new concepts in processing and product design, exploiting renewables and finding better ways to manage the reuse of finite resources. A fundamental necessity is to break through the classical boundaries between material types that have characterised European thinking over past decades.

EU funding on Materials Research under FP5 and FP6

FP5€349.9 million301 projects

FP6€458.2 million142 projects

A D E C A D E O F E U - F U N D E D R E S E A R C H 5

of European industry

New levels of performance

As FP6 gives way to FP7, the latest models of manufac-turing industry continue to identify materials as a prime factor in increasing the value of products and their per-formance. New research will focus on multifunctional materials and functionalised surfaces with tailored prop-erties targeting a wide range of applications, while also taking account of potential impacts on health, safety and the environment throughout their entire life-cycles.

Emphasis will continue to be placed on the benefits to be obtained from exploration of nanotechnologies and biotechnologies to produce manufactured materials that outperform those found in nature. Calls for proposals will foster a multidisciplinary approach that involves chemis-try, physics, engineering sciences, and theoretical and computational modelling.

Materials characterisation, design methods and simulation techniques are also crucial to improve our understanding of materials, in particular the structure-property relation-ships at different scales, and to extend the ability to employ virtual materials in the design process. Support for the integration of nano-molecular-macro levels in chemical and materials technologies will give rise to new concepts and processes in key areas such as in catalysis, and in pro-cess intensification and optimisation, which have great relevance to many sectors of European industry.

Priority topic for EU support

Materials research was identified as a strong candidate for EU support under successive RTD Framework Programmes. It clearly warrants investment in multidisciplinary and multi-sectoral transnational collaboration in order to reach critical mass, and is an essential component of the emerging European Research Area.

In the Fifth Framework Programme (FP5) covering 1998-2002, Materials was classified as a ‘generic activity’, playing a supporting role to key actions in the Competi-tive and sustainable growth (GROWTH) programme. A total of 301 projects in Materials Research received EC funding of €350 million.

The FP6 (2002-2006) budget was nearly 31 % larger, with a Community contribution of €458 million to 142 gen-erally larger-scale Materials projects under the Theme ‘Nanotechnologies and nano-sciences, knowledge-based multifunctional materials and new production processes and devices’ (NMP).

A selection of success stories from these two periods is outlined in the following pages.

Total number of projects in FP6 per subarea (€458.2 million)Total number of projects in FP5 per subarea (€349.9 million)

36

41

46

58

21

48

27

22

12

27

2519

8

53

Polymers and their composites

Materials for energy applications

Surface engineering and coatings

Materials for information

technologies

Materials with high mechanical

performances

Catalysis and chemical technologies

Biomaterials and medical implants

Polymers and theirs composites Catalysis and

chemical technologies

Biomaterials and medical implants

Materials for energy applicationsSurface engineering

and coatings

Materials for information

technologies

Materials with high mechanical

performances

Success stories in FP5

Types Number of EC funding contracts AM 8 €0.9 millionCR 73 €32.8 million MC 40 €4.8 million NAS 1 €1.4 million NAS2 9 €1.6 million RS 163 €299.1 million TN 7 €9.3 million Grand Total 301 €349.9 million

AM = Accompanying MeasuresCR = Cooperative Research (CRAFT) ProjectsMC = Marie Curie ActionsNAS = New Acession States ActionsNAS2 = New Accession States Actions 2RS = Research ProjectsTN = Thematic Networks

The 301 projects supported correspond to the following topics published in the calls:

• Cross-cutting generic materials technologies• Advanced functional materials• Sustainable chemistry • Expanding the limits and durability of materials

Thixoforming is a promising technology that combines the advantages of casting and forging for the production of near-net shaped piece parts. Forged parts have excel-lent mechanical properties, but cannot be realised with the degree of shape complexity that is possible with cast-ing. The main drawback of casting, however, is that due to eventual defects and a dendritic microstructure, the parts are not suitable for safety-relevant applications.

In thixoforming, the raw material is heated to above its liquidus temperature, which causes it to behave thixo- t ropically, i.e. its viscosity decreases with time due to shear stresses. Thanks to this effect, it is possible to produce high quality parts with improved shape-forming capability.

Lean, green process

The main objective of the project ADAPTED STEEL PARTS was to develop technology and equipment for the series production of thixoformed steel parts. Furthermore, it had to be proven that the developed process would be able to compete, both economically and ecologically, with other contemporary production technologies.

To respond to this challenge, the scope of work within the project covered the following fields:• adaptation and re-design of an automotive part to the

requirements of thixoforming;• adaptation and modification of various steel grades;• inductive heating of the steel billets, control and

handling;• basic forming tests and FEA (finite element analysis)

simulations;• process development (engineering) and automation;• development of tool materials for thixoforming of steel;• testing of the redesigned and thixoformed parts under

industrial conditions;• determination of the economic benefits.

Project successes

Automated process demonstrated. By the end of the project a fully automated process line for the production of a secondary air-flange (SKL-Flange) was available and a small series of these parts was produced.

Special steel developed. A low carbon steel grade, known as C38L2T, was developed specifically for thixo-forming purposes and investigated to determine the opti-mal rolling and casting conditions.

Simulation model validated. A simulation model for the inductive heating of steel billets was developed and experimentally validated. Experiments were carried out to characterise the behaviour of selected steel grades when formed under semi-solid conditions.

System concepts realised. Concepts for the handling system, tool and heating device of an automated thixo-forming production line were introduced and realised.

G5RD-CT-2002-00684 – Adapted Steel Parts Development of adapted steel parts forged under semi-solid conditions for the industrial marketTotal cost: €1 937 154 | EC contribution: €1 208 575Project duration: December 2002 – June 2006 (43 months)Coordinator: Dirk Fischer – IFUM – Institute of Metal Forming and Metal Forming Machine Tools, Leibniz University of Hanover, Germany

One-step process to complex, high performance steel parts (2002-2006)


Stages for the production of

SKL-flanges by drop forging

(above), re-designed SKL-flange

produced by thixoforming in

only one step (below).

Today, more than 500 000 hip- and knee-joint replace-ments are fitted annually throughout the European Union. Such procedures are extremely successful in restoring mobility to sufferers from arthritic and other degenerative conditions. However, the average lifetime of a hip pros-thesis, for example, is around 10 to 15 years – with active and heavyweight patients being particularly prone to premature failure. This clearly poses a quality-of-life problem for younger and other vulnerable recipients. Moreover, revisionary surgery can increase the cost of the original operation by a further 70 to 100 %, adding around €260 million a year to EU medical costs.

Search for more durable materials

Ceramic materials are now considered as alternatives to the common metal femoral heads articulating against an acetabular cup of polyethylene, or to a metal-metal bear-ing device. These materials appear to be ideally suited for joint prosthesis because of their hardness, which results in low wear rates and excellent biocompatibility.

However, ceramic materials are known to be brittle and susceptible to slow crack growth. Consequently, signif-icant in-vivo failure is reported by the orthopaedic community, due to the failure of the currently used alu-mina ceramic components after periods in service.

To provide longer lasting and secure hip implants, there is a clear need for ceramic materials with high stability and improved mechanical properties compared with alumina. In the three-year BIOKER project, a consortium of research institutes and industrial partners from three EU countries therefore investigated the development of alumina nano-composites to form ceramic-ceramic implants with potential life-spans of more than 30 years.

Project successes

Fracture-resistant nanocomposites. BIOKER developed a new family of alumina-zirconia nanocomposites ex-hibiting fracture resistance properties beyond those so far achieved with oxide ceramics, opening the way to application in orthopaedics.

Novel process developed. The nanocomposites were obtained by an innovative industrial process using powder alkoxide mixtures. A thorough study of the fatigue behav-iour of these composites was conducted to establish the safe operating range.

Sophisticated prototypes manufactured. Prototypes of complex shape, with roughness as low as 2 nm, were successfully prepared by using pressure casting techno logy coupled with a new 3D polishing method able to cope with the shape complexity of the implants. Polished pro-totypes were used to validate tribological performance and their adaptability in biomedicine.

Extensive testing completed. The long-term perform-ance of prosthetic hip and knee joint specimens was evaluated in simulators, in order to compare wear and fatigue behaviour with that of commercial products. Cytotoxicity, genotoxicity and particle debris analyses were performed, showing clear superiority to conventional materials. Finally a dossier relevant to hip and knee com-ponents was prepared in accordance with the requirements of Directive 93/42/EEC.

Nanocomposite ceramics make longer-lasting artificial joints (2001-2004)

G5RD-CT-2001-00483 – BIOKER Extending the lifespan of orthopaedic implants: development of ceramic hip and knee prostheses with improved zirconia toughened alumina nanocompositesTotal cost: €4 101 087 | EC contribution: €2 050 540Project duration: January 2001 – August 2004 (44 months)Coordinator: Ramon Torrecillas – INCAR-CSIC, Madrid, Spain


Alumina-zirconia

nanocomposite powders

obtained by a reaction-

precipitation route, as

starting powders for longer

lasting ceramic implants.


G5MA-CT-2002-00014 – BREWMedium and long-term opportunities and risks of the biotechnological production of bulk chemicals from renewable resources – the potential of white biotechnologyTotal cost: €892 529 | EC contribution: €451 890Project duration: January 2003 – April 2005 (28 months)Coordinator: Martin K. Patel – Utrecht University, Utrecht, the Netherlands

Biotechnologically produced organic chemicals from biomass offer new potentials (2003-2005)

Making polymers and other organic chemicals from bio-mass could be a sustainable alternative to today’s reliance on fossil fuels. Industrial biotechnology, also referred to as ‘white biotechnology’, is already making considerable in-roads in the production of pharmaceuticals, fine chemicals and specialty chemicals, but questions remain about the scope and extent of its potential role in the manufacture of bulk chemicals. In the Support Action BREW, a con-sortium of six European institutes and nine large-scale chemical companies studied which products might be made in this way, and whether it could be environmentally preferential, economically attractive and acceptable in terms of risks and public acceptance.

Project successes

The main findings of the BREW study can be summarised as follows:

Energy use is key. Using white biotechnology for bulk chemicals production offers very substantial opportuni-ties to reduce non-renewable energy use, greenhouse gas emissions and related environmental impacts; but the challenge is primarily economic. Most of the 14 products studied already exhibit lower non-renewable energy use and greenhouse gas emissions when manufactured biotechnologically, with maize as the feedstock. Greater savings would be made if lignocellulosic feedstocks could be used in the future, while fermentable cane sugar would be even more economical.

Economic conditions crucial. In an unfavourable eco-nomic climate (low oil prices, high sugar prices, etc.) the share of bio-based chemicals remains marginal (see fig-ure, case ‘LOW’). Under more favourable conditions – i.e. up to 85 US$/barrel oil and 70-200 €/t fermentable sug-ar, substantial technological innovation and 3.0 % p.a. growth – by the year 2050 up to two thirds of the non-renewable energy can be saved compared with the amount required to produce the same compounds from petrochemical feedstocks. This equates to 7 600 PJ non-renewable energy use and to 480 million tonnes CO2 equivalents in the EU-25 (see figure, case ‘HIGH’).

Land use and Macroeconomic savings. Total land use for bio-based chemical production is relatively low in most scenarios. The economic assessment shows that white biotechnology offers substantial macroeconomic savings, reaching up to €75 billion by 2050.

Non-renewable energy

savings and greenhouse gas

emission reduction in the

scenarios HIGH and LOW for

lignocellulosics and starch

as feedstock (EU-25, until

year 2050).Greenhouse gas (GHG) emission reduction(million tonnes CO2 equivalents)

600

500

400

300

200

100

0

2000 2010

High – Lignocellulosics

High – Starch

Low

2020 2030 2040 2050

Savings of non-renewable energy(1 PJ = 1 Petajoule = 1015 Joule = 23.9 million tons of oil equiv.)

8 000

7 000

6 000

5 000

4 000

3 000

2 000

1 000

0

2000 2010

High – Lignocellulosics

High – Starch

Low

2020 2030 2040 2050


G5RD-CT-2000-00267 – DISC Novel intervertebral disc prosthesesTotal cost: €6 000 564 | EC contribution: €2 842 166Project duration: January 2001 – July 2005 (54 months)Coordinator: Luigi Ambrosio – National Research Council of Italy, Istituto per i Materiali Compositi e Biomedici, Naples, Italy

Back pain is a major problem afflicting the workforce in industrialised countries today. Low back pain is the second most common cause of missed work days and is the lead-ing cause of disability between the ages 19-45. It is the most prevalent principal impairment in occupational inju-ries, and eight out of ten people will have a problem with back pain at some time during their lives. Intervertebral disc degeneration is one of the major causes of low back pain. Currently available artificial disc implants for the spine are less than ideal, because they require complex surgical procedures for placement, and are prone to wear and degeneration.

Bid to mimic natural tissues

Using a problem-solving approach, the partners of the DISC project aimed to carry out breakthrough research to mimic the natural structure of the disc tissues and to engineer biofunctional devices that would assure dura-bility, safety and easy surgical implantation. Additional goals included the reduction of implant failure rates, an increase in biocompatibility and minimisation of surgery time and costs.

Project successes

Acellular nucleus substitutes. By its completion, the work had led to the development of two acellular inject-able nucleus substitute materials: one was made from a hyaluronic-acid-based photo-linked derivative; the other contained three main components – PEG-acrylate, PEG-mercaptopropionate and a starter for polymerisation.

Stem-cell-loaded nucleus substitutes. One cell-loaded nucleus material – the amide of hyaluronic acid (HYA) – can act as a delivery system for nucleus and stem cells, and is capable of supporting cell growth, as well as being injectable, biocompatible, biodegradable and exhibiting appropriate mechanical properties. A second, which is a PEGVS-peptide hydrogel showing similar capabilities, was also delivered under the project.

Intervertebral disc prostheses. An artificial disc was de-signed and prepared, consisting of two end-plates made of hydroxyapatite-reinforced polyethylene composite and a composite hydrogel as annulus-nucleus system.

Cell culturing techniques. The partners developed tech-niques for the isolation and culturing of marrow stem cells.

Spinal inserts relieve lower back pain (2001-2005)

PEGVS-peptide gels

loaded with bone

marrow stem cells:

14 days (left) and

28 days in culture

(right).

Biomimetic Composite

Intervertebral Disc

Prosthesis.

HYA-based gel loaded

with bone marrow stem

cells: 14 days in culture.


G5RD-CT-2002-00752 – MATINOESNovel organic-inorganic materials in opto electronic systems for the monitoring and control of bio-processesTotal cost: €1 998 158 | EC contribution: €1 229 987Project duration: November 2002 – March 2006 (39 months)Coordinator: Patricia Scully – CEAS, University of Manchester, Manchester, United Kingdom

Enzyme-based sensors allow bio-process optimisation (2002-2006)

Affordable and rapid sensing techniques are required in many different fields: biotechnological processes for the food, drinks and pharmaceutical industries; synthesis of biofuels; waste processing and environmental protection. There is a need for continuous in situ monitoring of reac-tants in biotechnological production processes, often under harsh reaction conditions, where analytes of interest include glucose, fructose, glycerol and oxygen.

When such processes are controlled by off-line sampling and remote analysis, the time delays in results feedback prevent optimisation. In some cases, the bio-reactants may be too low in concentration or unsuitable for direct detec-tion, requiring enhancement by an appropriate transducer. But many transducers cannot directly measure bio-reactants due to interference by pH or temperature, making it neces-sary to immobilise biomolecules as chemical transducers at the detection site.

Extremely demanding criteria

The MATINOES project aimed to develop optical sensors using enzymes as biochemical transducers incorporated into hybrid coatings placed on an optical surface. Desired advantages include robustness to sterilisation procedures, stability and reliability over an extended period, applica-tion over a wide dynamic range, no interference with the sterile barrier, insensitivity to protein adsorption and sur-face growth, and resistance to degradation or enzymatic breakdown.

The work comprised several stages: • development of inorganic-organic hybrid coatings

(Ormocer®) to immobilise enzymes and fluorescent chem ical transducers as claddings on optical compo-nents such as lenses and fibres;

• purification and modification of enzymes for immobi-lisation into the optical coatings;

• development of optical detection systems for on-line monitoring of bioreactions by fluorescence;

• testing of sensor prototypes in a laboratory biotechno-logical reactor and in real biotechnological processes.

Project successes

Layers optimised. Double and single layer coatings have been optimised for immobilisation of enzymes for sens-ing glucose over a concentration range of 0-30 mmol/l, with a detection limit of 0.5 % (vol) and activity over 30 days in a bioreactor.

Target molecules detectable. Enzymes have been immobilised to sense sucrose, alcohols, lactose and D-amino acids.

Instruments tested. Instrumentation and sensors to measure oxygen and glucose were installed in a fermen-tation vessel of industrial partner Moorepark, and the glucose sensor was validated using fermented apple juice (cider) provided by a commercial cider producer.

Wide dissemination. The project generated over 50 pub-lications and presentations; one patent was filed and a DVD was produced to explain the sensor operation and applications.

Sensor probe

deconstructed to show

details of probe ending.

Laboratory bioreactor

with two MATINOES

probes (optical oxygen

sensor and optical

glucose sensor).

Tessellation of various optical

sensors using enzymes

as biochemical transducers,

incorporated into

hybrid coatings.


G5RD-CT-2002-00819 – SOCRAX Expanding the limits of single crystal superalloys through short crack fracture mechanics analysisTotal cost: €3 438 112 | EC contribution: €2 096 740Project duration: December 2002 – February 2007 (51 months)Coordinator: Franck Gallerneau – Office National d’Études et de Recherches Aérospatiales (ONERA), Structure and Damage Mechanics Department, Châtillon, France

The future operation of aero-engines and industrial gas tur-bines is closely linked with higher efficiency, lower costs and increased safety. These requirements can be met as a result of improvements to both materials and design methods. Because first-stage turbine blades and vanes are subjected to severe and complex thermo-mechanical loading under degrading environmental conditions, their design has a major impact on the engine as a whole.

Significant progress in materials processing and enhanced properties has led to the use of single-crystal superalloys in both small and large blades, with intricate cooling arrangements. However, these materials can only be used to full advantage if improved and well-validated life methodologies are introduced in the design and maintenance stages.

Improved life prediction methods will result in superior and lighter turbine components, with longer service life than current design methods allow. This will lead to a reduction in the consumption of raw materials and also to a signifi-cant decrease of operating costs, since it will also increase the interval between costly replacement of parts.

Understanding single-crystal superalloys

The goal of SOCRAX project was to determine how more efficient use could be made of single-crystal superalloys in gas turbine blades for both aero-engines and land-based gas turbines. The specific objectives of the work programme were:

• characterisation of short and long crack propagation in single-crystal superalloys. The experimental programme included simple and complex loading conditions as well as more complicated specimen geometries;

• development of fracture mechanics methodologies to account for the behaviour of single crystals – including more advanced methods in terms of mechanistic models and local approaches to fracture that involve the coup-ling between all the significant physical and mechanical processes;

• application of these methodologies for the life assessment of single-crystal superalloy components, the service lives of which are controlled by short crack behaviour.

Project successes

Insight into parameters. Acquired creep-fatigue crack growth data have established the effect of loading fea-tures such as varying frequency, dwell period, temperature, load ratio and the oxidising environment – as well as the role of crystallographic orientation, a key issue for the application of single crystal superalloys.

Design models producing results. Specific deformation models are now well integrated in the finite element codes used by the industrial partners and can be applied in the design assessment of actual components.

Simulation reproduces damage modes. Creep-fatigue models based on fracture mechanics have been extended and applied to single crystal superalloys, and mechanistic models have been developed to simulate the complex coup ling of crack tip inelastic deformation, oxidation, local damage and crack.

Predictions stand the test. The life prediction crack growth methods were finally validated on complex test-piece geometries and loadings representative of actual aeronautical and industrial gas turbine components.

Single-crystal superalloys make aero-engines safer (2002-2007)

Simulation of the plastic

wake zone due to crack

growth under loading

with overloads.

SEM micrograph of single

crystal superalloy along

the crack path.

Success stories in FP6

Types Count of Sum of Eff Contracts Contract AmountCA 2 €1.5 millionIP 16 €158.3 million IP SME 2 €6.8 million NoE 14 €102.9 million SSA 9 €2.3 million STREP 99 €186.4 million Grand Total 142 €458.2 million

CA = Coordination ActionsIP = Integrated ProjectsIP SME = Integrated Projects dedicated

to Small and Medium EnterprisesNoE = Networks of ExcellenceSSA = Specific Support ActionsSTREP = Specific Targeted Research Projects

The 142 projects supported correspond to the following topics published in the calls:

• Knowledge-based multifunctional materials• Development of fundamental knowledge• Understanding materials phenomena • Modelling and design of multi-functional materials • Interfacial phenomena in materials • New generation of tools for advanced materials characterisation • Methods of computational modelling of multifunctional materials • Technologies associated with the production, transformation and processing

of knowledge-based multifunctional materials and biomaterials• Mastering chemistry and creating new processing pathways

for multifunctional materials • Surface and interface science and engineering • Materials processing by radically innovative technologies • Development of nanostructured materials • ‘Intelligent‘ biomaterials for tissue repair and regeneration • Tribology-related surface engineering for multifunctional materials • Advanced materials processing • Development of nanostructured porous materials • Multifunctional ceramic thin films with radically new properties • Engineering support for materials development• New materials by design • New knowledge-based higher performance materials for macro-scale applications • Materials by design: bio-inspired materials and organic/inorganic hybrid materials• New knowledge-based higher performance multi-materials

for macro-scale applications• Measurement and testing of new multi-functional materials• Mapping and foresight activities on multi-functional materials• Materials by design: multifunctional organic materials• Materials for solid state ionics


Multifunctional nano-materials sourced from renewable cellulose(2004-2006)

In the AEROCELL project, ten partners from universities, research institutions, SMEs and industry focused on producing completely new types of ultra-light nano- or sub micro porous multifunctional cellulose materials (collec tively described as ‘aerocellulose’) that might be used for packaging, batteries, electrodes for fuel cells, super-capacitors, encapsulation for cosmetics and nutrition, thermal insulation and much more.

New research correlations

This project is a good illustration of the need to bring together multidisciplinary teams to prepare new advanced materials based on integrated knowledge, inventing novel processes and opening new application fields for bio-degradable materials from renewable resources. Preparation of such a new class of materials required the acquisition of basic know ledge in several research areas – e.g. cellulose physics, chemistry and processing, aerogel science, electro-chemistry and the controlled release of substances – that had not previously been correlated. The tremendous pos-sibilities opened by these materials are reflected in the strong industrial representation among the consortium.

The overall objective was to understand the various ways of producing aerocellulose, and subsequently to tailor the process to the requirements of a series of applications:• a carrier system for detergents, cosmetics or nutrition; • a carbon cylinder for electrochemical uses;• a biodegradable and compostable material.

Project successes

Samples characterised. More than 500 aerocellulose sam-ples were produced and characterised. A major problem of shrinkage during supercritical CO2 drying was addressed and remedied by an optimised drying process.

Pyrolysis loss reduced. Another problem of enormous mass loss (<95 %) during pyrolysis was reduced to about 80 % – which is an excellent result for the pyrolysis of cellulosic materials.

Carrier applications confirmed. The technical suitability of Aerocellulose as a carrier was demonstrated, as was the technical feasibility of pyrolysed Aerocellulose for carbon electrodes in batteries and fuel cells.

NMP-CT-2003-505888 – AEROCELL Aerocellulose and its carbon counterparts – porous, multifunctional nanomaterials from renewable resourcesTotal cost: €4 250 745 | EC contribution: €2 299 376Project duration: January 2004 – December 2006 (36 months)Coordinator: Hedda Weber – Lenzing AG, Lenzing, Austria

Carbonised aerocellulose

samples produced

by several partners.

Volume shrinkage of an acetogel

from cellulose acetate (left) during

supercritical CO2 drying, to (right)

the finally obtained aerogel.


NMP3-CT-2004-500160 – AIMs Advanced interactive materials by designTotal cost: €19 712 232 | EC contribution: €11 400 544 Project duration: April 2004 – March 2008 (48 months)Coordinator: Andrzej Górak – University of Dortmund, Germany

Interactive materials beat bottlenecks to new pharmaceuticals(2004-2008)

The market for biopharmaceuticals is growing fast – and continued research advances plus projects in the pipeline are likely to foster further growth. An ageing population and the associated increase in diseases like cancer and disorders of the cardiovascular, autoimmune and central nervous systems provide significant demand for new biopharmaceuticals. With oncology as the focal point for many biotechnological projects, the use of monoclonal antibodies to target specific cells is an area of particular interest.

Beating the bottlenecks

However, the emerging drugs also pose a challenge for the global healthcare system, since their production is expensive and capacities are limited. Recent develop-ments in the production of cell supernatants have shifted the bottleneck towards the purification part of the pro-cess. Effective technologies are needed to provide fast, cost-effective and sustainable design of downstream processes for new biopharmaceuticals.

In order to establish such design procedures, the Inte grated Project AIMs combined multidisciplinary expertise from 24 scientific and industrial partners representing 12 Euro-pean countries to:• design new interactive materials with improved perform-

ance in the purification of monoclonal antibodies;• improve understanding of material/product interaction by

experimentally validated molecular modelling strategies;• develop new purification technologies with high capacity;• integrate material and process design to enhance process

efficiency at an early development stage;• establish reliable computer-aided design strategies with

high flexibility.

Project successes

Enhanced separation media produced. New chroma-tographic beads with tuneable properties and enhanced mechanical stability were developed and produced, as were affinity membranes with open pore structures of significantly enhanced capacity.

Interactions predicted. The partners predicted the inter-action between support, ligand, and product for different types of system.

Working systems developed. As well as developing a continuous chromatographic unit for the purification of monoclonal antibodies with ion-exchange materials, the team developed and scaled-up a multi-stage aqueous two-phase extraction unit for the purification of mono-clonal antibodies.

Process modelling accomplished. New computer models permitted detailed investigation of the chromato-gra phic, membrane separation and extraction processes.

SEM image of an

affinity membrane with

open pore structure.

Final structure of the system IgG

(green), ligand (orange), linker

(yellow), and support (blue).

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NMP3-CT-2003-505953 – ASTERIXE Development of advanced surface technology for extended resistance in extreme environmentTotal cost: €2 768 847 | EC contribution: €1 638 667Project duration: January 2004 – December 2006 (36 months)Coordinator: Pierre Juliet – CEA – Commissariat à l’Énergie Atomique, Grenoble, France

Raising the efficiency of turbines by increasing their work-ing temperatures is of key importance in both the energy generation and aeronautical fields. A breakthrough has been provided by the development of thermal barrier coatings (TBC) deposited by plasma spray. With the use of new e-beam-based technologies, significant further improvement can be expected.

Innovative surface engineering

In the ASTERIXE project, 11 partners from five European countries aimed to develop innovative surface treatments leading to high performance barrier coatings suitable for operation in high temperature, highly corrosive envi-ronments under high mechanical stress conditions. They sought to open new routes to surface engineering by combining electron beam physical vapour deposition (EBPVD) coating and a pulsed electron beam (PEB) surface post-treatment process.

The detailed project objectives were to:• enhance coating adhesion strength by simultaneously

melting the coating and the substrate surface;• reach surface coating densities and toughness close

to the theoretical bulk values by extremely fast surface quenching from the melt without affecting the substrate material;

• obtain hitherto unavailable chemical coating compositions by combining multilayer coating and surface alloying;

• develop a self-diagnostic coating (or sensor coating) by insertion of luminescent oxides in the yttria-stabilized zirconia (YSZ) top layer;

• derive a methodology for ‘on-line’ temperature measure-ment employing the above-mentioned sensor coatings in EBPVD production technology.

Project successes

PEB treatment densification was shown to double bond-coat lifetime, while an additional improvement was obtained by Zr surface alloying. Dopant insertion improved the TBC stability, enabling it to withstand temperatures up to 1 500 °C.

The feasibility of on-line temperature measurement at up to 1 400 °C inside a thermal barrier sensor coating produced by EBPVD was achieved with suitable dopant insertion. This significantly exceeds the initial project tar-get of 800 °C. The ability to monitor the thermal history of the TBC using the sensor coating technology was also demonstrated.

These very promising results related to both bond-coat and YSZ layers open the way for a new generation of thermal barrier coating systems of advanced and multiple functionality.

Advanced surface technology makes turbines more efficient(2004-2006)

Samples under realistic

test conditions.


NMP3-CT-2003-505614 – BARP+ Development of a bioartificial pancreas for type 1 diabetes therapyTotal cost: €3 622 479 | EC contribution: €2 495 600Project duration: January 2004 – December 2006 (36 months)Coordinator: Alain Belcourt – CeeD – Centre Européen d’Études du Diabète, Strasbourg, France

Bioartificial pancreas could end insulin injections for diabetics(2004-2006)

Four to five million people in Europe and about 80 million worldwide suffer from type 1 diabetes characterised by deficient insulin secretion and resulting in hyperglycaemia (an elevated concentration of glucose in the blood). This doubles the risk of death from coronary diseases and can lead to acquired blindness or chronic renal failure.

Apart from transplantation of the pancreas or of pancre-atic tissue ‘islets’, the only form of therapy is to administer insulin by daily multi-injections or implantable pumps.

Several research groups have developed methods to gather large numbers of pancreas islets from pigs. Unfor-tunately, transplantation of these into humans would induce a severe immune rejection, which can probably only be avoided by encapsulating them within protective semi- permeable membranes.

As around one million islets are required to restore the gly-caemic balance of a typical diabetic, this is far from simple. Various encapsulation methods have been explored in the past, but with only limited success. The BARP+ project investigated a new system that shows great potential.

The goal was to develop a prototype bioartificial pancreas suitable for encapsulation of insulin-secreting tissue and small enough for implantation into the human body. The device is required to provide selective permeability to insulin and glucose, while excluding other molecules responsible for rejection or unwanted toxic effects.

Project successes

Prototype developed. Islets of animal origin were enclosed in a device formed by a support and a polycarbonate mem-brane, with an extra-cellular matrix in the encapsulation chamber to prevent aggregation of the islets. By association of 20 devices in a plate-type support, it was possible to implant up to 20 000 pancreatic islets, as necessary for testing on a mini-pig.

Device tested in mini-pig. Two new models of type 1 diabetic pig were developed. Sterile macrodevices were implanted into normal mini-pigs and their biocompatibil-ity studied after up to 92 days of implantation. Despite the induction of fibrosis, there was no observable inflamma-tory response, nor any significant effect on the peripheral immune system.

Conditioning, sterilization and packaging. A method for the preparation of human pancreatic islets led to clear-ance of contaminants in 94 % of cases, thus demonstrating the feasibility to provide islets for seeding. Ethylene oxide (EtO) was used to sterilize the membranes and the various parts of the device. Specifications for storage and shipping in the presence of fluorocarbon were defined.

Alternative insulin-secreting cells evaluated. Novel insulin-secreting cells were evaluated and two selected: RINm5F-GK and MING capable of forming pseudo-islets. It proved easily possible to accommodate up to several hundreds of such pseudo-islets in the device.

Graft survival confirmed. Studies demonstrated that col-lagen had no effect on the viability and functionality of islets. Fluorocarbons were shown to have a beneficial effect on tissue preservation and, by preventing cell adhe-sion, to improve cell viability. Moreover, these emulsions promoted the formation of insulin-producing pseudo-islets from ß-cell lines.

Further development of the device. Membrane improve ment followed two axes: new treatments of the polycarbonate film; and conception, testing and devel-opment of intelligent multilayers. Addition of vascular endothelial growth factor (VEGF) to the surface treatment of the membrane or its inclusion in a multilayer established at the surface induced neo-vascularisation of the system. A second generation device was manufactured, including inlets and outlets, with an integrated system of septa to drain the old material and fill with fresh cells.

VEGF effect on vascularisation

at the membrane surface

after seven days, respectively

without (above) and with

(below) addition

of growth factor.

Effect of fluorocarbons

on cell adhesion.


NMP3-CT-2005-516858 – HIPERCHEM High performance nanostructured coated conductors by chemical processing Total cost: €2 341 350 | EC contribution: €1 700 000Project duration: April 2005 – December 2008 (45 months)Coordinator: Xavier Obradors – ICMAB – Consejo Superior de Investigaciones Científicas, Barcelona, Spain

Nanostructured superconductors pave the way to high temperature/high magnetic field applications (2005-2008)

High temperature superconductivity is a key enabling tech-nology for the development of efficient electrical energy management incorporating renewable energy sources, for use in new medical technologies based on magnetic resonance or, in the longer term, in fusion generators. This vision relies on achieving cost-effective conductors with high performance at high temperatures in high magnetic fields.

The goal of mass fabrication of superconducting tapes at low cost can be achieved with innovative chemical solution deposition methodologies, where a multilayered structure is generated on a metallic substrate, leading to new types of tape known as ‘coated conductors’.

The architecture of these conductors needs to be as simple as possible to minimise manufacturing costs, but supercon-ducting layers based on the compound YBa2Cu3O7 must be nanostructured in order to achieve high performance. Current carrying capacities 100 times higher than those of copper wires can be achieved.

In order to achieve these characteristics, the HIPERCHEM project focused on four main areas:• advancing the knowledge of the growth of epitaxial

superconducting layers based on two chemical solution deposition methodologies – metal-organic decomposition and hybrid liquid phase epitaxy;

• preparing nanostructured interfacial oxide templates, based on strain-induced self-assembling or track-etched polymer coatings, which can generate a network of artificial defects in the superconducting layer acting as vortex pinning centres;

• developing innovative chemical solution processing metho dologies for the preparation of epitaxial supercon-ducting film nanocomposites ensuring vortex pinning at high film thickness;

• generating simple coated conductor architectures inte-grating the most promising nanostructuring approaches for scaled-up production with excellent specifications.

Project successes

World-beating nanocomposites. YBa2Cu3O7-BaZrO3 nanocomposite superconducting films produced by chemi-cal processing achieved world record performance in terms of vortex pinning efficiency.

Structures compatible with epitaxial growth. Oxide nanostructures were prepared by self-assembling and by track-etched polymer template growth based on chemical solution methods. Both interfacial structures are compat-ible with the growth of epitaxial superconducting layers.

Rapid growth rates. Superconducting films (above 1 μm), were produced at high growth rates (above 1 nm/s) with high quality epitaxial structure and high critical currents by chemical solution processing methods.

Large-scale manufacture possible. Simplified conduc-tor architectures have been obtained for different types of flexible metallic substrate that enhance the large-scale manufacturability of the coated conductors.

TEM micrograph of a superconducting

nanocomposite. Nanodots of BaZrO3

(~10-20 nm) are randomly distributed within

a superconducting YBa2Cu3O7 matrix, which

becomes strongly disordered. Non-coherent

interfaces promote the formation of

intergrowths, dislocations and plane buckling,

strongly modifying the nanostructure and

superconducting properties.


NMP3-CT-2003-505790 – HIPERMAX High performance industrial protein matrices through bioprocessingTotal cost: €4 257 412 | EC contribution: €2 997 283Project duration: March 2004 – May 2007 (39 months)Coordinator: Elisabeth Heine – DWI an der RWTH Aachen e.V., Aachen, Germany

Over millions of years, nature has evolved fibrous materi-als such as wool, silk, leather and feather, with unique physical and chemical structures giving rise to remarkable combinations of surface and bulk properties. The HIPER-MAX project team sought to build on these matrices through bioprocess engineering, introducing innovative enzymatic technologies to modify and improve the estab-lished materials with a view to their exploitation in various industrial sectors.

The project covered five main areas:• analysis and definition of the accessibility of target

groups in the natural proteins e.g. amino, hydroxyl, sulf-hydryl, carboxyl or carboxamide;

• screening for novel enzymes to catalyse the modification of surface and bulk properties of the protein matrices, fol-lowed by production of those enzymes at pilot scale;

• mechanistic investigations of the enzymatic reactions on modelled and real substrates;

• exploitation of novel enzymes for surface and bulk modification of the protein matrices in order to develop engineered materials.

In particular, new applications developed for poultry feather were shown to offer opportunities for its commer-cial use as a valuable fibre and protein stream. It can thus now be regarded as a novel sustainable material, rather than as a waste by-product destined for landfill or burning, with all of the associated environmental impact.

Project successes

Target groups identified. New knowledge has been acquired on the accessibility of target groups for tyrosi-nase in silk and wool proteins; available transglutaminase enzymes suitable for protein modification; and the availability of glutamine in wool fibres and leather for transglutaminase (TGase).

Production process innovation. Several important pro-cess advances were achieved:• fibre processing technologies using mixed feather pulps

permitted the manufacture of novel packaging materials such as egg cartons and plant pots that were of compa-rable quality, if not better, than commercial products;

• phenol- and thiol-containing functional molecules were incorporated in wool and silk fibres using Trichoderma tyrosinase;

• enzyme-catalysed functionalisation enabled anti-odour compounds to be incorporated into leather;

• silk protein-polysaccharide bioconjugates and cross-linked silk fibroin-gelatin blend films were produced;

• enzyme-catalysed functionalisation of protein-contain-ing nerve grafts proved possible.

Novel enzyme products. Five novel bacterial TGase genes were cloned; novel tyrosinase was derived from Tricho-derma reesei; new sulphydryl oxidases (SOX) were screened and Aspergillus oryzae SOX was fully characterised.

Bioprocessing improves on natural materials (2004-2007)

Wool fibre with grafted gliadin via

TGase catalysis (bound gliadin was

detected using a gliadin-specific

antibody and an FITC-labelled

secondary antibody).

Prototype egg mould produced

from mixed feather pulp.


NMP3-CT-2004-500635 – IMPRESS Intermetallic materials processing in relation to earth and space solidification Total cost: €41 000 000 | EC contribution: €15 887 797Project duration: November 2004 – October 2009 (60 months)Coordinator: David Jarvis – European Space Agency, Noordwijk, the Netherlands

Intermetallic alloys are compounds of two or more met-als, having a variety of attractive properties that can be exploited in industrial products. Two specific examples under study in the IMPRESS Integrated Project are light-weight TiAl alloys and catalytic NiAl powders.

This five-year initiative brings together a multi-disciplinary team of 160 experts from across Europe and Russia, under the coordination of the European Space Agency (ESA). Its scientific objective is to understand the critical links between the processing, structure and properties of these novel intermetallic materials. Technologically, the goals are to produce lighter TiAl turbine blades for use in aero-engines and stationary gas turbines, and advanced NiAl catalytic powders for incorporation into hydrogen fuel cells and hydrogenation reactors. In addition, an ultimate environ-mental aim is to develop high-value products that can significantly reduce CO2 and NOx pollution, in line with the Kyoto Protocol and future policies.

Experiments in space

Experiments performed in a space environment, such as on board the International Space Station or other plat-forms available to the ESA, provide the team with unique benchmark samples. They yield critical information about microstructural evolution, hydrodynamic effects and defect formation during the solidification of these special alloys. Other space experiments will deliver precise thermo-physical property data unattainable on the ground. The combination of experiments, theory, space research and predictive computer modelling will greatly aid industry in its quest to develop the next generation of products.

Project successes

New casting techniques. Mid-way through the project, investment casting techniques have been developed for the production of prototype TiAl-based turbine blades for high-temperature application. A patented alloy and heat treatment process have also been developed, ena-bling higher performance turbine blades.

Novel hydrogenation catalysts. Production of micro-metric and nanometric NiAl-based powders using gas atomisation and vapour synthesis processes has also been realised. These catalysts have tuneable structures that make them useful for a variety of hydrogenation reac-tions in the chemical industry.

Space tests performed. Launch of the TEXUS 43 and 44 sounding rockets, with an onboard electromagnetic levitation device in weightless conditions, permitted pre-cise measurement of various liquid alloy properties as a function of temperature and under cooling.

Development of validated computer models of alloy solidi fication, casting and powder production are further results of the space experimentation.

Novel intermetallic alloys for ‘green’ applications (2004-2009)

Electromagnetic levitation

device flown onboard a TEXUS

sounding rocket.

Turbine blades produced by

centrifugal investment casting.

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NMP3-CT-2003-505267 – LIGBANK The European Ligand Bank: An Innovation FacilityTotal cost: €2 463 000 | EC contribution: €2 150 000Project duration: January 2004 – December 2006 (36 months)Coordinator: Simon Woodward – School of Chemistry, The University of Nottingham, Nottingham NG7 2 RD, United Kingdom

Ligand bank speeds process development (2004-2006)

New metal-catalysed processes form a fast growing sector of the global fine chemical and pharmaceutical industries. The key requirement in realising such processes is the iden-tification of reaction additives, called ligands, which strongly promote the desired metal-based catalysis.

Arriving at a successful new process can often entail the screening of more than100 candidate ligands. And, while this is a relatively rapid procedure, synthesising the ligands themselves may require complex processes involving months of work, thus restricting the rate of discovery in both academic and commercial environments.

The objective of the LIGBANK initiative, coordinated by the University of Nottingham, UK, was therefore to create a central bank of ligand molecules that would be readily accessible to researchers.

Eight academic laboratories and an SME worked together, using chemical synthesis, combinatorial technology, and internet research to prepare a large collection of novel legends as the nucleus of the European Ligand Bank, a web-based forum promoting the exchange of ligands, related additives and other information on catalysis.

As well as establishing the on-line facility, the partners aimed to demonstrate its applicability by using the infor-mation to discover one or more new commercial products or processes.

Project successes

Growing user base. The website at www.ligbank.com boasts an ever-expanding number of users. Membership is now open to all of the European catalytic chemistry com-munity, including those in industry.

New ligands discovered. Among identified ligands and additives with exceptional properties is the trimethyl-aluminium analogue DABAL – which is an air-stable white powder, although its parent spontaneously combusts in air! The DABAL compound has been commercialised in partnership with the Sigma-Aldrich Chemical Company and may be used for the preparation of secondary chiral alcohols (useful pharmaceutical building blocks).

Breakthrough methods. New patent-protected, in situ quench methods for the preparation of pyridyl amino-alcohols ligands allow their rapid synthesis in flow and carousel reactors.

Extensive publication. More than 50 scientific papers have been published on new catalytic processes, including unprecedented approaches to chiral Reformatsky reactions leading to beta amino acids.

Follow-up action. The project has promoted the formation of a new COST Action in innovative catalysis en com passing over 20 EU countries.

Comparison of air-stable DABAL and its pyrophoric parent trimethylaluminium.


NMP3-CT-2005-013653 – LIVEBIOMATDevelopment of new polymeric biomaterials for in vitro and in vivo liver reconstructionTotal cost: €3 023 922 | EC contribution: €2 299 906 Project duration: April 2005 – September 2008 (42 months)Coordinator: Augustinus Bader – University of Leipzig, Biomedizinisches-Biotechnologisches Zentrum, Leipzig, Germany

The development of new intelligent materials able to activate specific responses in primary human liver cells (hepatocytes) could provide an inexpensive means of studying hepatic diseases and infections, and eventually point the way to regeneration of the liver itself.

Isolated hepatocytes rapidly lose their specific functions when maintained under standard in vitro cell culture condi-tions, so a new approach is crucial to the investigation of hepatocyte activity in a controlled environment. Engineered liver tissue constructs would form valuable tools for pre- clinical drug testing and toxicology studies, leading to improved technologies for the production of pharmaceuti-cals and vaccines. To meet this need, LIVEBIOMAT targeted the design and development of new bioactive polymeric membranes and scaffolds for the reconstruction of an in vitro liver tissue model. In addition, expansion of rat liver progenitor cells on bio-membranes was tested. During this process a significant amount of knowledge about the appli-cation of stem cell and progenitor research in the biomaterial field has been generated that is fully novel and significant for the advancement of the field.

More ambitiously, the partners also aimed to develop bio-degradable polymers for the in vivo reconstruction of liver tissue, representing an important advance in the pre-vention, diagnosis and treatment of problem diseases.

Project successes

Bioreactor construction. A small-scale bioreactor for primary hepatocyte cultures has been developed and characterised, capable of high throughput for in vitro pharma cological screenings. This system is being used to test the effect of the new polymeric biomaterials (polymeric membranes and peptide scaffolds) on the parameters for functional and genomic levels in primary rat hepatocytes.

Membrane trials. Semi-permeable polymeric mem-branes were prepared from a blend of modified poly ether ether ketone (PEEK-WC) and polyurethane (PU), with regularly distributed 0.1 μm surface pores. Primary hepatocytes cultured on this membrane surface exhi bited higher metabolic rates than those in collagen cultures. The polymer is compatible with human hepatocytes, and is thus applicable as a substrate for the in vitro reconstruction of human liver tissue. Surface modification. In order to optimise the mem-branes for biomolecule immobilisation, cell adhesion and expression of the hepatocytes’ metabolic functions, various glow discharge plasma modification processes (pdAA, plasma deposition from acrylic acid, grafting of nitrogen groups from NH3) were applied, followed by the immobilisation of biomolecules (RGD peptides, galactos-amine). The pdAA-modified surfaces were also used as substrates to promote the self-assembly of a peptide coat-ing (RAD16-I), without significant pore size alteration or structural change.

New nanofibre self-assembling scaffolds prepared. Scaffolds were modified with peptide cell-instructive motifs (peptides), and their capacity to maintain liver- specific activities was tested and compared with that of the classical collagen culture model using primary rat hepatocytes cultured in a sandwich configuration.

Hepatocyte constructs point the way to liver re-growth (2005-2008)

SEM image of the PEEK-WC-PU

membrane surface (above) and

human hepatocytes after one

month of culture on it (below).

Confocal laser micrographs of

human hepatocytes cultured on

the PEEK-WC-PU membrane by

actin staining (green), vinculin

(red) and CK19 (pink). Cell nuclei

were labeled with DAPI (blue).

The small-scale bioreactor

as a system for in vitro

pharmacological screenings.


NMP3-CT-2006-033221 – MACOMUFIManipulating the coupling in multiferroic thin filmsTotal cost: €4 800 000 | EC contribution: €2 400 000 Project duration: September 2006 – August 2009 (36 months)Coordinator: Wilfrid Prellier – CNRS, Caen, France

R&D and investment in electronics focus overwhelmingly on multifunctionality, which should meet the market demands for radically new components that are more com-pact, cheaper, and consume less power. Particular attention is being devoted to magnetoelectric (ME) multiferroics, which exhibit coupled ferromagnetic and ferroelectric prop-erties. Such materials allow reversal of their magnetisation by application of an electric field, and vice-versa.

ME materials can thus provide optimal solutions to many device-design problems, with a high potential impact on important segments of the electronics market, including high-density electric-field-controlled MRAM, HF wireless telecoms and spintronics. However, the physics of ME cou-pling is far from being understood. This limits know ledge-based research for materials with optimised properties, and ultimately prohibits industrial use of ME thin films.

First in its field

In order to accelerate the development of novel devices for European industry, the objective of the MaCoMuFi project is to manipulate the coupling in multiferroic thin films made of single phases, multilayers and nano-composite materials. It will set up the first systematic knowledge-based approach in the domain, involving the tight collaboration between experts in oxide synthesis, complex oxides modelling and device design.

The general aim is to understand, synthesise and control robust multiferroic materials in the form of thin films displaying a significant ME coupling at room temperature.

Project successes

Promising materials. Novel oxide thin films (down to 5 nm thick) have been identified, showing significant ME coupling (higher than 1V.cm-1Oe-1) at room temperature.

Proof of concept. Innovative electric field control of magnetic devices (spin filter, magnetic memory, agile filter…) is proven as a means of exploiting the properties of multiferroics.

Links identified. The partners have gained an under-standing of the relationship between process, structure and composition of the multiferroic oxide thin films.

Optimised production processes. Tailored methods are allowing refinement of the processes used for film production.

New techniques. Techniques for ME coupling measure-ment and nanostructural characterisation have been developed, and a software tool for the design of ceramic thin films with optimum ME properties is now available.

Magnetoelectric films promise power-saving electronic devices(2006-2009)

Magnetization loops measured after a field-cooling for a YMnO3

thin layer and a upper grown soft ferromagnetic permalloylayer

when a biasing voltage is applied.

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NMP3-CT-2003-505664 – NANOEFFECTS Nanocomposites with high colouration efficiency for electrochromic smart plastic devices Total cost: €4 435 799 | EC contribution: €2 429 990Project duration: April 2004 – September 2007 (42 months)Coordinator: Uwe Posset – Fraunhofer Institute for Silicate Research (Fraunhofer-ISC), Würzburg, Germany

Polymer nanocomposites reduce power demand for electrochromic eyewear (2004-2007)

Eyewear and safety goggles represent important markets worldwide and therefore offer big business opportuni-ties for European companies. There is a strong demand for products with efficient tuneable light transmission. Available photochromic lenses only partially fulfil this need, due to poor colour intensity in warm or low UV-A environments. However, past attempts to commercialise electrochromic spectacles as an alternative technology failed due to high production costs, slow switching, and a power consumption inducing the need for large bat-teries. The latter drawback, in particular, is incompatible with the requirement for lightweight spectacles having a cosmetically acceptable design.

Solution in sight

In response to this challenge the NANOEFFECTS project addressed five main areas: • development of new conductive polymer-based nanocom-

posite materials, plus assessment of their electro-optical performance and stability;

• studies to equip ophthalmic plastics with transparent conducting oxide films;

• design and characterisation of polymer electrolytes and ion storage layers suitable for use in spectacles;

• assembly and performance evaluation of all components in full electrochromic devices;

• scaling up and demonstrator preparation.

The pursued wet-chemical approach promises to over-come some of the existing limitations of electrochromic devices and provides the basis for a cost-effective solution.

Project successes

Chemical precursors produced. Development and scaled-up production of special types of precursors provide for in situ chemical oxidative polymerisation on conductive plastic substrates. Development of hydrophobic ionic liquid based polymer electrolytes.

Efficient nanocomposite films. Highly transparent conductive polymer based nanocomposite films were prepared, offering high colouration efficiency (colouring: up to 700 cm2/C; bleaching: up to 1500 cm2/C) and elec-trochromic contrast (change in optical density up to 0.8 for a film 200 nm in thickness).

Quality coatings realised. Very good coating quality, with extremely low surface roughness, was achieved via wet-chemical co-processing with polysiloxanes (roughness around 10 nanometres).

Fast-responding devices. Produced plastic electrochromic devices allow for a sudden colour change within seconds upon the application of a small electric voltage.

Product stability demonstrated. Cycle lifetime exper-iments indicated a high stability both for the active electrochromic layer (no delamination after repeated cycling in liquid electrolyte) and the full demonstrator devices, for which close to 105 deep potential cycles were realised. Colour adjustable. Development of a colour modifi-cation concept is supposed to permit adjustment of the colour of the darkened state towards neutral tints.

Nanocomposite-based plastic

electrochromic device.

Upper picture: bleached state.

Lower picture: darkened state.


NMP3-CT-2005-013944 – NANOPHOTO Nanocrystalline silicon films for photovoltaic and optoelectronic applications Total cost: €1 826 454 | EC contribution: €1 699 954Project duration: June 2005 – November 2008 (42 months)Coordinator: Sergio Pizzini – University of Milano-Bicocca, Milan, Italy

High material costs for bulk silicon and environmental risks associated with tellurides and selenides might be the final obstacles to full development of photovoltaics in the years to come. The use of thin nanocrystalline silicon (nc-Si) films would provide an answer to this problem, if their full poten-tialities in terms of low-cost technology and high conversion efficiency could be demonstrated.

As nc-Si is a distribution of silicon nanocrystals in an amor-phous silicon matrix, quantum confining effects might also be present, leading to additional applications in opto-electronics. However, the deposition of nc-Si films having an appropriate content of amorphous and crystalline phas-es in the right nanocrystal size range is a very difficult task, depending on a large number of independent variables.

Computational tools under development

In its bid to respond to this challenge, the NANOPHOTO project aims to develop computational tools capable of assisting the design and the operation of a new nc-Si growth process. The work covers four main areas:• deposition of nc-Si thin films using a plasma-enhanced,

low energy chemical vapour deposition (LEPECVD) reactor;

• computer modelling of a 2D and 3D low energy (LEP-ECVD) reactor, of the kinetics of surface reactions and of the 2D growth of nc-Si films;

• structural, electrical and optoelectronic characterisation of undoped and doped films;

• preparation of prototypes of solar cells and light-emit-ting devices.

Among anticipated breakthroughs is industrial adoption of the LEPECVD technique, bringing the advantage of high quality and very high throughput. In addition, the use of nc-Si can be foreseen as an alternative to α-Si in industrial applications such solar cells and flat displays, as well as in the development of LEDs operating over a wide range of energies.

Project successes

Progress in modelling. At the half-way project stage, development of a 2D model of the deposition reactor has been completed, fitting well with the analysis of the plasma distribution and composition on the median part of the reactor. Modelling of the silicon nanocrystal growth also closely matches the transmission electron microscope images.

Homogeneous films produced. Deposition of micro-scopically homogeneous films, consisting of a distribution of Si dots measuring a few nm in size in an amorphous silicon matrix, meets the requirements for both photo -vol taic and optoelectronic applications

Nanocrystalline Si films to cut cost of optoelectronics (2005-2008)

Modelling and deposition of microscopically homogeneous films, consisting

of a distribution of Si dots, a few nm in size, in an amorphous silicon matrix,

which fit with the requirements of both PV and optoelectronic applications.

Development of a 2D model of the deposition reactor, which well fits with the analysis

of the plasma distribution and composition on the median part of the reactor.


NMP3-CT-2004-505442 – NsHAPe Designed nanoscale heterogeneities for controlling water-borne pressure-sensitive adhesive performanceTotal cost: €2 018 465 | EC contribution: €1 502 044Project duration: October 2004 – September 2007 (36 months)Coordinator: Peter A. Lovell – University of Manchester, Manchester, United Kingdom

Environmental and health restrictions on emission of organic solvents from industrial processes have driven the development of water-borne pressure-sensitive adhesives (wb-PSAs), which are based on colloidally-stable aque-ous dispersions of polymer particles with diameters of 100-400 nm and whose composition, internal structure and surfaces can be controlled within dimensions of a few nanometres during synthesis.

Potential to meet industrial demand

Due to their socio-economic benefits, there is an increas-ing demand for wb-PSAs for high performance applications, particularly in the healthcare, aerospace, automotive, con-struction and assembly, and data tracking industries. However, limitations in high-end adhesive performance of wb-PSAs, particularly in bonding to non-polar substrates, needed to be overcome for these benefits to be realised.

The multidisciplinary NsHAPe project set out to develop new wb-PSAs that overcome present limitation and to inform the development of industrial-scale processes and proto-types for high-performance, commercially-viable products.

These objectives were achieved through the design, synthesis and characterisation of wb-PSAs of controlled nanoscale heterogeneity, and through characterisation and evaluation of their coatability, film formation, defor-mation mechanisms and adhesive performance.

Broader dissemination of the results is expected to help bring about technological advances in other coating industries.

Project successes

New adhesive formulations. Novel wb-PSAs were developed and patented, comprising structured latex par-ticles synthesised using mini emulsion polymerisation.

Performance characterised. Thorough characterisation of wb-PSA particle morphology and film formation was achieved using atomic force microscopy and other methods of surface analysis. Microscopic real-time defor-mation behaviour of wb-PSAs during probe tack and shear testing was also determined.

Process control improved. A new mechanism was established for controlling wb-PSA adhesive performance through controlled synthesis of core-shell latexes.

Water-borne adhesives eliminate solvent use (2004-2007)

Real-time probe-tack stress

versus strain curves obtained

at a removal rate of 100 μm

s-1 from both stainless steel

and polyethylene (PE)

substrates. The curves show

the far superior performance

of a new wb-PSA

(GME620011) developed

in the NsHAPe project

in comparison with the

industrial benchmark

wb-PSA (WB).

Atomic force microscopy

phase images of the surface

of an adhesive film formed

from a core-shell wb-PSA

before (left) and after (right)

cross linking between the

outer shells of the particles.

The brighter regions highlight

the higher modulus cross

linked regions.

(100um.s-1)

1.0

0.8

0.6

0.4

0.2

0

0 5

steel

WBGME620011

PE

steel

PE

10 15 20 25


NMP3-CT-2003-505478 – ODEON Design and fabrication of optoelectronic devices based on innovative second-order non linear organic nanomaterialsTotal cost: €3 780 100 | EC contribution: €2 625 000Project duration: February 2004 – July 2007 (42 months)Coordinator: Mauro Casalboni – University of Rome Tor Vergata, Rome, Italy

Electro-optic modulators are key devices in telecommuni-cation and information systems; they encode data into an optical signal for high speed transmission over fibre-optic cables. The properties of such modulators are based on second-order non-linearity of materials such as lithium niobate, which are characterised by the lack of a centre of symmetry.

The ODEON project was launched to break the deadlock arising from intrinsic limitations in modulation frequency of the existing materials, indicating that established techno logy had reached a performance plateau. The need for new and faster devices was evident, and it was believed that new materials would be able to provide alternative solutions.

A ‘soft matter’ approach opened new perspectives for innovative device fabrication based on organic molecules (chromophores) with high second-order non-linear optical activity. Such molecules can be dispersed in, or covalently bonded with, polymeric or glassy hybrid organic/inorganic sol-gel derived matrices. In order to be active as electro-optical devices, the chromophores must be oriented by a poling process to give an overall non-centrosymmetric system.

ODEON gathered the best European skills operating in the fields of functional polymers, sol-gel based materials, chromophore synthesis and device fabrication. Its specific objectives were to: • improve the performance of second order non-linear

chromophores, develop new families of molecules and model their non-linear properties;

• test chromophore compatibility with polymers and hybrid sol-gel based materials as a means to optimise loading stability;

• reach a higher degree of polar order in the functional materials;

• develop procedures to test the time-stability of the systems, in order to identify the optimal materials;

• determine the design and fabrication processes for a test device.

Project successes

Many new systems identified. Synthesis and charac-terisation of more than 60 new systems – chromophores, polymers, functionalised polymers and sol-gel based matri-ces containing active species – produced highly promising results in terms of application suitability.

Process guidelines set. Modelling of the poling process – including the composition of the guest chromophore, the host polymer and the effect of electric field – showed how to optimise the capability of the composite system for electro-optical switching.

Material/process compatibility. Two systems were selected for subsequent device test. The first is a very stable cross-linkable polymer based on bisdiazo-phenyl chromophore; the second is an optimised hybrid sol-gel material containing a suitable functionalised chromophore that is chemically bondable to the matrix backbone.

Production strategies defined. Two different litho-graphic strategies were envisaged for the two above systems. Other direct photolithography routes to high quality guiding structures were also developed.

Mach-Zehnder electro-optical modulators based on organic active molecules in polymeric and hybrid sol gel materials were studied and developed. A demonstra-tor was fabri ca ted using a standard photolithographic approach (waveguides and electrodes). Alternative fabrication methods were also analysed with a view to cost-effective device manufacturing.

Organics bring prospect of faster electro-optics (2004-2007)

3D computer modelling of

chromophore in a polymer

structure under electric field.


NMP3-CT-2004-001561 – RADSASRational design and characterisation of supramolecular architectures on surfacesTotal Cost: €1 868 820 | EC contribution: €991 500Project duration: October 2004 – September 2007 (36 months) Coordinator: Roman Fasel – Eidgenössische Materialprüfungs- und Forschungsanstalt (Empa), Dübendorf, Switzerland

Nanoscience has experienced a tremendous growth in importance over recent years, with a strong focus on the understanding and exploitation of the enormous richness of phenomena at nanometer scale. At the same time the massively parallel fabrication of nanodevices on an indus-trial level has emerged as a substantial bottleneck in the path to technological applications. Chemical methods of bottom-up construction become important in this con-text, because they offer the only routes to processes for the growth of complicated systems that are fast enough for efficient production of nano-electronics, nano-optics and other functional nano-systems.

Surface chemistry shows the way

The RADSAS project pursued the development of efficient strategies for parallel, two-dimensional molecular self-assembly on surfaces, which is an indispensable prerequisite for the technical realisation of bottom-up supra-molecular design and engineering. The central aspect of the partners’ approach was to introduce site selectivity not only in the molecular building blocks, but also in the interaction with the substrate surface. This was accomplished by the fab-rication of atomically well defined template surfaces, providing regular arrays of nucleation centres for the growth of rationally designed 2D supra-molecular assemblies.

Project successes

Site-specific anchoring of molecules. Regular, site-specific anchoring of single molecules or small molecular clusters was demonstrated and characterised in great detail for various template surfaces and a range of dif-ferent molecular species. The growth of extended binary supramolecular wires (single row and double row) along the step edges of the vicinal Au(11,12,12) surface was achieved. Strong site-specific adsorption of C42H18 (hexa-peri-hexabenzocoronene HBC) at kink sites of the {111} steps of the Au(111) surfaces has been elucidated in full theoretical and experimental detail.

Molecular geometry adapted. A variety of molecules was synthesised with specific geometries and bonding site configurations specially adapted to C2, C 3 and C4 template surfaces to form regular, supra-molecular networks on template surfaces with C2, C3 and C4 symmetry.

Efficient capture demonstrated. It could be shown that a monolayer of corannulene (C20H10) on Cu(110) acts as a very efficient host-guest system to capture individual C60 molecules. This contrasts with the same system in solution, where the molecular vibration of the corannulene inhibits C60 capture.

Tailored molecules lay foundation for efficient nanodevice production (2004-2007)

Double-row molecular wires from

bi-component self-assembly on Au(11,12,12)

at low coverage. The two molecules are

3,4,9,10-perylenetetracarboxylic diimide

(PTCDI) and 1,4-bis-(2,4-diamino-1,3,5,-

triazine)-benzene (BDATB).

Site-specific anchoring of

individual C60 molecules

(yellow balls) in the middle of

the fcc regions of the 2 ML

silver on Pt(111) strain relief

network, which serves as

template.


NMP3-CT-2003-505952 – SCGNano-structured self-cleaning coated glasses: modelling and laboratory tests for fundamental knowledge on thin film coatings, EC normalisation and customer benefitsTotal Cost: €3 748 472 | EC contribution: €2 289 584Project duration: March 2004 – February 2007 (36 months)Coordinator: Léthicia Gueneau – Saint-Gobain Recherche, Aubervilliers, France

How clean are self-cleaning windows? (2004-2007)

Glass that cleans itself when exposed to rain and sunlight is likely to enjoy major success in the EU, which consumes 45 % of the world’s window glazing: a share worth nearly €18 million. In fact, glasses with self-cleaning properties based on the hydrophilic and photocatalytic action of nano-structured surface layers have been available in Europe since 2001. At present, their penetration is a mere 0.2 % of the market. The future looks extremely promising, but could be compromised by the fact that performance standards have not yet been rationalised at an international level.

Currently, glazing is tested according to existing appropri-ate national or international standards to qualify optical and energetic properties. In building applications, for example, it must pass the EN-1096 standard. However, proposed standards for self-cleaning have so far been based mainly on the measurement of photocatalytic activity.

Now, project SCG has added new knowledge about the mechanisms involved, showing that superhydrophilicity also plays an essential part. Leading glass producers Saint-Gobain, France and Pilkington, UK, collaborated in a five-nation consortium that conducted extensive field experiments in polluted atmospheres at monitored test sites, to quantify the degradation and removal of con-taminants under real conditions. From their findings, standard laboratory test methods were developed for characterisation of the surface properties, and for behaviour comparison with standard float glass in a true atmospheric environment.

Project successes

Realistic tests defined. A link between outdoor perform-ance and the results of accelerated laboratory tests has been established.

In the laboratory, self-cleaning behaviour is simulated by spraying a model dirt onto the glass, then submitting it to UV and water spray (simulating rain). The soiling level is measured by means of the haze formed, which has been observed to be correlated with the perception of dirtiness level by an evaluation group.

Various glasses have been tested, including several commercial self-cleaning types, untreated float glass and hydrophobic glass The studies also provided an under-standing of the chemical and physical interaction between glazing sealants and self-cleaning glasses during their lifetime.

Standardisation underway. The draft procedure was published in March 2007. A calendar has now been defined to propose the test to the certification committees.

Left: SGG BIOCLEAN®

photocatalytic

self-cleaning glass.

Right: Ordinary float

glass.

Left: Ordinary float glass.

Right: Pilkington Activ™ hydrophilic

self-cleaning glass.


NMP3-CT – 2004-500311 – SUSTAINPACKInnovation and sustainable development in the fibre based packaging value chainTotal cost: €29 737 728 | EC contribution: €16 791 930Project duration: June 2004 – September 2008 (52 months)Coordinator: Kennert Johansson – STFI-Packforsk AB, Stockholm, Sweden

Packaging involves all partners in the supply chain – from production and manufacturing, through filling, warehous-ing and distribution, to retailers and consumers. Together they impose often diverse and contradictory demands on the functionality of packaging materials. The search for true innovations that reconcile all these needs makes research in the field an extremely wide-ranging activity.

The SUSTAINPACK Integrated Project mobilises partners from 13 EU countries in a large-scale effort to develop and implement a sustainable packaging tool platform based on renewable wood-fibre. This could help to estab-lish Europe’s forest industry cluster as a powerful player in global packaging markets.

Addressing both materials and processes, the platform covers several key areas:• nano-reinforcement, involving the addition of nanoclay

particles and nanofibres, as a means to increase the strength of fibre-based materials, thereby allowing sub-stantial material savings;

• renewable composite materials, combining cellulose fibres with other renewables such as whey, wheat glu-ten or shrimp-shell derivatives, to provide enhanced mechanical, optical and barrier properties;

• protective coatings, targeting improving water resist-ance, barrier properties and resistance to mechanical distortion;

• 3D packs, using cellulose-fibre composites as sustain-able alternatives for petroleum-based materials;

• communicative packaging, embracing printing and coat-ing technologies, information technology and packaging design to develop novel sensors and bioactive compounds.

Project successes

Range of demonstrators. Seven packaging demonstrators bringing together all the materials/process developments made in the project will show to the public at large the progress of research in SUSTAINPACK areas.

Improved composite films. Development of equipment for production of nanoclays and nano-fibres tailor-made for different polymer matrices has led to major improve-ments in flexible film performance.

Materials-saving process. Pilot-scale production of multiply paperboard will demonstrate reduced material consumption with retained properties.

Self-healing coatings. Micro-encapsulated self-healing agents in coatings halt or heal cracks in the surface of fibre-based materials.

Thermoformable composites. Thermoformed compos-ites with improved moisture and water uptake properties were produced.

Innovations in sensing. A food-grade printable relative humidy indicator and printable low cost time-tempera-ture logger have been produced. Use of a mobile phone to read out 2D-barcodes in visible or invisible inks can also be demonstrated.

‘Smart’ packaging vital to a sustainable future (2004-2008)

The healing effect of microcapsules on

cracks in paperboard.

TEM of nano-cellulose,

15-29 nm thickness.

How to obtain EU publications

Our priced publications are available from EU Bookshop (http://bookshop.europa.eu), where you can place an order with the sales agent of your choice.

The Publications Office has a worldwide network of sales agents. You can obtain their contact details by sending a fax to (352) 29 29-42758.

European Commission

EUR 23581 EN – Success stories in the materials field – A decade of EU-funded research

Luxembourg: Office for Official Publications of the European Communities

2008 – 32 pp. – 21 x 29.7 cm

ISBN 978-92-79-09669-3DOI 10.2777/96506

Acknowledgements

The authors express their thanks for the contributions of the coordinators and the programe officers of the projects.Furthermore, the collaboration of Mike Parry, Michael Horgan, Charlotte Andersdotter and Bingen Urquijo Garay is acknowledged.

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Advanced intelligent materials providing new functionalities, improved performance and greater versatility for different applications are critical drivers of innovation in virtually every sector, from transport and construction to energy, electronics and healthcare. Materials research was identified as a strong candidate for EU support under successive Research Framework Programmes. It clearly warrants investment in multidisciplinary and multisectorial transnational collaboration in order to reach a critical mass, and is an essential component of the emerging European Research Area. Over 400 projects have been financed during the 5th and 6th Framework Programmes in materials research, and this publication highlights the main achievements.

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