Neu entwickelte TiAl‐Basislegierungen für den Leichtbau von Triebwerks‐ und Motorkomponenten – Eigenschaften,Herstellung, Anwendung

Newly Developed TiAl Base Alloys for Lightweight Components in Jet Engines and Internal Combustion Engines – Properties, Production, Application Titanium aluminides are a most promising high temperature materials alternative to conventional heat‐resistant steels and superalloys for high‐performance automotive and aircraft engine applications. Intermetallic TiAl base alloys offer striking advantages for high temperature and mechanical loading applications. The specific weight of about 3.8 ‐ 4.1 g/ccm is low, the oxidation and burn resistance at temperatures up to 800 °C are good. The elastic stiffness is high and the temperature strength is enhanced. Feasible applications in combustion engines are valves, pistons and exhaust gas turbocharger rotors. Blades, vanes and discs for jet engines are under development, as well. Due to the extraordinary high specific Young’s modulus (ca. 46 GPa ccm/g) and 0.2 %‐yield strength up to 1 GPa of the TiAl base alloys in the as‐extruded state some applications at lower temperatures have also been taken into consideration, e.g. connecting rods and piston pins. The paper reviews constitutional related properties of the advanced TiAl base alloys with the respect to the industrial manufacturing of components and structural applications.     

Ermittlung von Berechnungskennwerten an Karosseriewerkstoffen – Bericht über ein Gemeinschaftsprojekt der Stahl‐ und Automobilindustrie

Determination of input data for numerical design of sheet steels – Report on a common research project of the steel and automotive industry Within the scope of a common research project of the steel and automotive industry, 20 sheet steels have been investigated to obtain input data for FE‐analysis. In detail, elastic, plastic and fatique characteristical values were determined by several testing institutes for a period of 3 years. The investigated sheet steels differ with regard to the microstructure and the steel concept. Beside several ferritic steels, multiphase steels like dual phase‐, complex phase‐ and TRIP steels as well as 2 austenitic stainless steels were characterised. The starting materials and selected steels with a defined predeformation and heat treatment were investigated. Within this project, the partners developed a testing and documentation precept in which the ways and means were fixed to reach the defined steel condition and to enable a standardised testing and data output for the material database, realised by the automotive industry. Before the actual elastic, plastic and fatique testing, a reception test for all steels was carried out to characterise the materials with regard to the microstructure, surface condition, chemical composition and mechanical properties, obtained in the quasistatic tensile test. The results of the different testing institutes (elastic, plastic and fatique) will be presented in separate publications in detail. As a result of this project it became obvious that the investigated steels can be divided into steel groups which show a similar strain hardening behaviour. Thus, a prediction of mechanical values and flow curves for cognate steels within one steel group seems to be possible. This subject will be the focus of further investigations within the scope of a new project started on January 1^st, 2003.     

Neue Methoden zur Beurteilung der Betriebsfestigkeit im Fahrzeugauslegungs‐ und ‐absicherungsprozess

Advanced durability evaluation in vehicle design and validation process The modern process of evaluation and validation conducted in the automotive industry uses experimental, metrological, and calculation‐based methods. Offering various examples, the present paper describes new developments in the determination and evaluation of operating strength, particularly in terms of virtual methods and their application in practice. The first point considered is the virtual determination of load data, the second is the improvement of calculated fatigue life. Two current examples in the development of methods are presented in this context: The first example examines the inhomogeneity of materials in calculating aluminium castings. The second example describes the approach taken in the configuration of components made of short‐fibre‐reinforced polymers, applying a new method of calculation.     

Mo‐Si‐B Alloys for Ultrahigh‐Temperature Structural Applications

A continuing quest in science is the development of materials capable of operating structurally at ever‐increasing temperatures. Indeed, the development of gas‐turbine engines for aircraft/aerospace, which has had a seminal impact on our ability to travel, has been controlled by the availability of materials capable of withstanding the higher‐temperature hostile environments encountered in these engines. Nickel‐base superalloys, particularly as single crystals, represent a crowning achievement here as they can operate in the combustors at ～1100 °C, with hot spots of ～1200 °C. As this represents ～90% of their melting temperature, if higher‐temperature engines are ever to be a reality, alternative materials must be utilized. One such class of materials is Mo‐Si‐B alloys; they have higher density but could operate several hundred degrees hotter. Here we describe the processing and structure versus mechanical properties of Mo‐Si‐B alloys and further document ways to optimize their nano/microstructures to achieve an appropriate balance of properties to realistically compete with Ni‐alloys for elevated‐temperature structural applications.     

Patterning π‐Conjugated Polymers

π‐Conjugated polymers show promise as active materials in application areas such as microelectronics, electro‐optics, opto‐electronics, and photonics. A critical feature in this emerging technology is device fabrication and the reproducible deposition of active material. This review focuses on current trends in the spatial deposition of conjugated polymers.     

3D‐Printed Scanning‐Probe Microscopes with Integrated Optical Actuation and Read‐Out

Scanning‐probe microscopy (SPM) is the method of choice for high‐resolution imaging of surfaces in science and industry. However, SPM systems are still considered as rather complex and costly scientific instruments, realized by delicate combinations of microscopic cantilevers, nanoscopic tips, and macroscopic read‐out units that require high‐precision alignment prior to use. This study introduces a concept of ultra‐compact SPM engines that combine cantilevers, tips, and a wide variety of actuator and read‐out elements into one single monolithic structure. The devices are fabricated by multiphoton laser lithography as it is a particularly flexible and accurate additive nanofabrication technique. The resulting SPM engines are operated by optical actuation and read‐out without manual alignment of individual components. The viability of the concept is demonstrated in a series of experiments that range from atomic‐force microscopy engines offering atomic step height resolution, their operation in fluids, and to 3D printed scanning near‐field optical microscopy. The presented approach is amenable to wafer‐scale mass fabrication of SPM arrays and capable to unlock a wide range of novel applications that are inaccessible by current approaches to build SPMs.     

Oxidation protective coatings for γ‐TiAl – recent trends

Engine designers show continued interest in γ‐TiAl based titanium aluminides as light–weight structural materials to be used at moderately elevated temperatures. Although alloy development has made significant progress in terms of mechanical properties and environmental resistance, protective coatings have been developed that help to extend the lifetime of these alloys significantly. The major challenge of coating development is to prevent the formation of fast growing titania. Furthermore, changes of coating chemistries at high temperatures have to be considered in order to avoid rapid degradation of the coatings due to interdiffusion between substrate and coating. The paper describes recent work of the authors on different coatings produced by means of magnetron sputter technique. Thin ceramic Ti‐Al‐Cr‐Y‐N layers tested at 900 °C exhibited poor oxidation resistance. In contrast, intermetallic Ti‐Al‐Cr, Si‐based and aluminum rich Ti‐Al coatings were tested at exposure temperatures up to 950 °C for 1000h resulting in reasonable and partially excellent oxidation behaviour.     

Self‐Assembled α‐Cyanostilbenes for Advanced Functional Materials

In the specific context of condensed media, the significant and increasing recent interest in the α‐cyanostilbene (CS) motif [? Ar? CH?C(CN)? Ar? ] is relevant. These compounds have shown remarkable optical features in addition to interesting electrical properties, and hence they are recognized as very suitable and versatile options for the development of functional materials. This progress report is focused on current and future use of CS structures and molecular assemblies with the aim of exploring and developing for the next generations of functional materials. A critical selection of illustrative materials that contain the CS motif, including relevant subfamilies such as the dicyanodistyrylbenzene and 2,3,3‐triphenylacrylonitrile shows how, driven by the self‐assembly of CS blocks, a variety of properties, effects, and possibilities for practical applications can be offered to the scientific community, through different rational routes for the elaboration of advanced materials. A survey is provided on the research efforts directed toward promoting the self‐assembly of the solid state (polycrystalline solids, thin films, and single crystals), liquid crystals, nanostructures, and gels with multistimuli responsiveness, and applications for sensors, organic light‐emitting diodes, organic field effect transistors, organic lasers, solar cells, or bioimaging purposes.     

Magnesium – der Zukunftswerkstoff für die Automobilindustrie?

Magnesium – future material for automotive industry? Magnesium alloys show a very high potential in automotive applications as constructive metal, whereas the main focus lies on die cast parts. Electronic industry is the major commercial consumer for die castings besides the automobile industry. Room temperature applications like steering wheels and frame components in cars as well as mobile phone‐ or notebook housings are well established. These castings are produced with AZ‐ or AM‐magnesium alloys, which show good room temperature properties and a good castability. The great alloy development challenge in extending the use of magnesium cast alloys are application for higher temperatures. The application in powertrain components is considered to be the benchmark here. Besides alloy development there are also further research activities in development of casting processes. Semi‐solid processes like New‐Rheocasting (NRC), Thoxomolding ? or Thixocasting (TC) are adapted to the requirements of newly developed alloys. Not only cast alloys but also magnesium wrought alloys have moved to the centre of interest in the last decade. Alloy development for improving the formability on the one hand as well as process development in extrusion or rolling has to be done in order to find optimum parameters for deforming magnesium alloys properly.     

Eigenschaften und Anwendungen von Chemisch Nickel‐Dispersionsschichten

Properties and applications of electroless nickel composite coatings This paper discusses the variety of composite electroless coatings used in different industrial applications. The inclusion of particulate matter within electroless nickel deposits can add entirely new properties to the plated layer. Composites with hard particles like diamond, silicon carbide and boron carbide provide greater wear resistance and the possibility for adjustable friction properties. Composite electroless nickel with diamond or ceramics has found wide applications in the textile, automotive and mechanical engineering industry. Friction joints in automotive engines constitute an important field of application for diamond coatings. Modern internal combustion engine designs require that the crankshaft and camshaft be fitted at a specific relative angle. In order to establish the correct angle during assembly and maintain it over the life of the engine, axial press‐fit joints in combination with centrally located retention bolts are employed. Failure of either the joints or the bolts can result in serious damage to the engine. The torque transfer ability of these engine components can be significantly increased by incorporating a friction foil that is diamond‐coated on both sides. Composite coatings with coarser diamond particles can be used for the coating of precision tools in the semiconductor industry. Enhanced lubricity can be achieved by incorporating solid lubricants in electroless nickel deposits. Composite coatings with PTFE or PFA offers non‐stick surfaces with antiadhesive properties and good resistance against adhesive wear. Because of the temperature and softness limitations these coatings are best suited for lower temperature and light loading applications. Electroless nickel boron nitride coatings can withstand temperatures up to 600 °C. This coating reduces coefficient of friction and wear in dynamic applications. A further application is the coating of molds for rubber and plastic components.     

Spanende Bearbeitung von Bauteilen aus Al‐Matrix‐Verbundwerkstoffen

Machining of Components of Al Matrix Composites The microstructure of metal matrix composites consists of hard reinforcements which are embedded in a metal matrix. The high hardness of the reinforcements leads to a difficult processing of these materials. The present paper demonstrates the machining of components of Al matrix composites for the automotive and the aircraft industry. The components are SiC particle reinforced brake drums, cylinder blocks with local Si particle and Al₂O₃ short fiber reinforced cylinder liners and TiB₂ particle reinforced extrusion molding profiles. The investigations illustrate that good results can be achieved when machining these components by turning, boring, drilling and milling with polycrystalline diamond (PCD) or CVD diamond thick‐film cutting tool materials.     

Self‐Similar Growth of Polyolefin Alloy Particles in a Single Granule Multi‐Catalyst Reactor

In this news article, a new kind of in‐reactor alloying process (Chinese multi‐catalyst reactor granule technology, CMRGT) is introduced. It provides the possibility to produce series of new polyolefin materials that can be used in automotive and appliances parts by the substitution of some traditional engineering plastics. A characteristic ‘fractal (self‐similar) growth and pore‐filling mechanism’ for the CMRGT‐produced alloy particles is found. It reveals the fundamental scientific principles that govern the chemistry and physics in the formation mechanism of such novel olefinic alloys. This mechanism allows a detailed control of the dispersion and structure of these polyolefin alloys from a nanometer to micrometer size range, and possesses great potential to fulfil the requirements for a new generation of recyclable automotive materials.     

An integrated solution for NOx‐reduction and ‐control under lean‐burn conditions

Upcoming emission regulations order highly effective NO_x‐reduction systems in lean‐burn engines requiring new catalytic materials and integrated control of the reduction process. Thus, new approaches for NO_x‐reduction and its monitoring over an On‐Board‐Diagnostic (OBD) system are suggested throughout the globe. A promising attempt is the development of a catalytic system having an integrated NO_x‐sensor, based on selective catalytic reduction process and impedance sensors. The study displays the results achieved both with a perovskite type of self‐regenerative catalyst functioning by H₂‐reductant and with impedance NO_x‐sensors. The catalysts were tested at the temperature range of 150 °C to 360 °C yielding NO_x conversion rates of 92 % with high selectivity to N₂. Impedance sensors having NiCr₂O₄‐ and NiO‐SE and PYSZ‐ and FYSZ‐electrolytes are developed and tested at 600 °C under lean atmosphere (5 vol. % O₂). Better sensing behaviour towards NO and lower cross‐selectivity towards O₂, CO, CO₂ and CH₄ have been observed with sensors having NiO‐SE.     

Möglichkeiten der Geruchsmessung und ‐minderung bei Naturfaserverbunden

Possibilities of Odour Measurement and Reduction of Natural Fibre Plastics The critical attitude of the German public concerning environmental questions has also invaded the world of odours. The evaluation and reduction of odours when using plastic materials has gained increasing significance in the last years. The packaging industry that produces wrapping materials for food and other consumables was the first to test for odours. During the last years the automobile industry has also shown increased interest in pinpointing and measuring odours, not only because of the increased usage of natural fibre reinforced plastics in car interiors, but also because of the general increase of concern over clean air. Natural fibre reinforced plastics, besides having advantages compared to glass‐ and carbon reinforced materials (mechanical properties/weight, CO₂‐equilibrium) also have properties that limit their application possibilities. Emissions and unpleasant odours at certain temperature and humidity conditions are of concern. To determine the origin of odour in bonded materials the single component, production step or their combination causing it has to be found. To achieve odour neutrality in plastics is difficult since production methods or additives can only be determined through prolonged testing and where the human nose is still more important than all the physical electronic measuring methods. The origin of odours and their importance for the well being and health of the population is questioned and forces not only the plastics industry to react. The is why both, plastics‐ and automobile industries are trying to react to the tendencies of the market place and it is the goal of the auto industry to deliver the most odour‐neutral new car.     

Gesenkschmieden hochfester Magnesium‐Knetlegierungen für Bauteile der Automobil‐ und Luftfahrtindustrie

Die‐forging of high strength magnesium wrought alloys for the automotive and aerospace industry Forging is an attractive method to produce complex components from magnesium alloys. In this context it is important to choose adequate processing parameters. Magnesium forgings provide superior quality, they are pressure sealed, free of pores and shrinkage and have excellent mechanical properties. The potential of magnesium forgings is very promising, but usage of magnesium forgings is still limited mainly due to the present cost situation.     

Surface Treatments of Automotive Parts – Research and Applications

Surface treatments used in daily manufacturing of parts for the automotive industry are selected to serve functional and decorative requirements achieved of mass production. Increased loads (mechanical, thermal etc.), longer life time, weight reduction, friction reduction, and corrosion resistance are demanded for modern automotive systems. Within the last decade, improved and new deposition techniques were developed in PVD, PECVD, thermochemical heat treatment and thermal spraying. These new treatments are becoming more and more common in powertrain and engine applications. Generating optimized surfaces for different types of substrate materials (e.g. Al‐ alloys, case hardened steels etc.) and geometries (e.g. bores) also impacts the running costs. Due to the new developments within these competing surface treatments, it becomes more and more common to substitute traditional treatment‐substrate‐systems with advanced treatments. Both the application potential and selected examples of different surface treatments will be shown. Aspects of the internal coating of bores inside the engine by plasma spraying, features of the corrosion protection of parts for the powertrain by the IONITOX process and piston ring treatments are discussed in more detail.     

Plastics in automobiles at SITEV '81

In the March 1981 edition of Materials in Engineering (P149) D. Charlesworth ‘Potential use for plastics in Automobiles’, reviewed in terms of materials properties and processing methods the advantages and limitations of plastics in comparison with metals. In order to convince car makers of the potential of plastics, materials suppliers and component manufacturers develop prototype parts which are publicly displayed, often for the first time, at motor shows. The most important of these shows is the International Exhibition of Suppliers to the Vehicle Industry (SITEV). SITEV '81 took place in Geneva and the more significant new applications of plastics to automobile components are reviewed and their likelihood of adaption by the automotive industry assessed in this article by Dr. N.A. Waterman who is a consultant on materials selection to the plastics and automotive industries.     

Solution Adsorption Formation of a π‐Conjugated Polymer/Graphene Composite for High‐Performance Field‐Effect Transistors

Semiconducting polymers with π‐conjugated electronic structures have potential application in the large‐scale printable fabrication of high‐performance electronic and optoelectronic devices. However, owing to their poor environmental stability and high‐cost synthesis, polymer semiconductors possess limited device implementation. Here, an approach for constructing a π‐conjugated polymer/graphene composite material to circumvent these limitations is provided, and then this material is patterned into 1D arrays. Driven by the π–π interaction, several‐layer polymers can be adsorbed onto the graphene planes. The low consumption of the high‐cost semiconductor polymers and the mass production of graphene contribute to the low‐cost fabrication of the π‐conjugated polymer/graphene composite materials. Based on the π‐conjugated system, a reduced π–π stacking distance between graphene and the polymer can be achieved, yielding enhanced charge‐transport properties. Owing to the incorporation of graphene, the composite material shows improved thermal stability. More generally, it is believed that the construction of the π‐conjugated composite shows clear possibility of integrating organic molecules and 2D materials into microstructure arrays for property‐by‐design fabrication of functional devices with large area, low cost, and high efficiency.     

Automatic remeshing in 3‐D analysis of forming processes

Finite element modelling, employing updated Lagrangian techniques, is used extensively in the design and analysis of bulk forming processes. However, the full 3‐D capability has not seen widespread use in the automotive, aerospace, and, related industries due to, among other reasons, the need for remeshing, or, representation of the workpiece with a new finite element mesh as the analysis progresses. Automating the remeshing procedure of the deformed workpiece geometry would reduce the time required for a 3‐D analysis by several orders of magnitude. This paper discusses an algorithm for generating a new mesh to represent the deformed workpiece geometry during the analysis. The procedure is used to perform a 3‐D analysis of a valve forging problem. Copyright © 1999 John Wiley & Sons, Ltd.     

Self‐Assembly of Hyperbranched Polymers and Its Biomedical Applications

Hyperbranched polymers (HBPs) are highly branched macromolecules with a three‐dimensional dendritic architecture. Due to their unique topological structure and interesting physical/chemical properties, HBPs have attracted wide attention from both academia and industry. In this paper, the recent developments in HBP self‐assembly and their biomedical applications have been comprehensively reviewed. Many delicate supramolecular structures from zero‐dimension (0D) to three‐dimension (3D), such as micelles, fibers, tubes, vesicles, membranes, large compound vesicles and physical gels, have been prepared through the solution or interfacial self‐assembly of amphiphilic HBPs. In addition, these supramolecular structures have shown promising applications in the biomedical areas including drug delivery, protein purification/detection/delivery, gene transfection, antibacterial/antifouling materials and cytomimetic chemistry. Such developments promote the interdiscipline researches among surpramolecular chemistry, biomedical chemistry, nano­technology and functional materials.