Completed projects

AiF-Nr.22641 N | EFDS-Nr. IGF-20/10

Project-No. 01IF22948N | EFDS Nr. IGF-20/11

period: 01.07.2023 – 31.12.2025

research institution

Fraunhofer-Institut für Werkzeugmaschinen und Umformtechnik IWU, Chenitz
Fraunhofer-Institut für Schicht- und Oberflächentechnik IST, Braunschweig
Fraunhofer-Institut für Werkstoff- und Strahltechnik IWS, Dresden

Abstract

PEM fuel cells offer enormous potential for reducing greenhouse gas emissions. However, their current use is limited by uneconomical large-scale production. The aim of this project is to develop and test new production routes for metallic BPPs. This includes the combination of two different coating approaches and forming processes:
Solution approach 1: Here, functional carbon layer systems are produced that are intended to retain their high electrical conductivity and corrosion resistance even after forming. A comparison between ARC evaporation and magnetron sputtering is carried out here. HIPIMS is also taken into account.
Solution approach 2: In this new production method for BPP, contrary to the current state of the art, a metallically pre-coated plate is functionalized after forming by a plasma diffusion treatment in order to minimize defects as a result of forming and to avoid corrosion initiation sites.
Solution approaches for forming: Three different processes are to be used for forming (hollow embossing, embossing rolls, hydroforming). Integration of solution approaches from the PA: The participating PA and in particular the participating SMEs are given the opportunity to apply their own coatings and have them analyzed or evaluated in order to compare their own state of the art with that of research and to secure a technological advantage. The direct benefit of the research results for SMEs arises above all from the increased know-how regarding the properties and limits of the coating and forming processes investigated and their effect on the operating conditions of the BPP, which is developed together with participating large companies and scientific institutions. This knowledge gives the companies involved a competitive edge.

Final Report BPP-Schicht [PDF]

Poster BPP-Schicht [PDF]

Success Note BPP-Schicht [PDF]

Publications

“Comparison of Magnetron-Sputtered and Cathodic Arc-Deposited Ti and Cr Thin Films on Stainless Steel for Bipolar Plates” | Publikation im MDPI Materials 2024 |
Fredebeul-Beverungen, N.; Steinhorst, M.; Roch, T. | Materials 2024, 17, 2864.
https://www.mdpi.com/1996-1944/17/12/2864

AiF-Nr. 22449 N | EFDS-Nr. IGF-19/14

period: 01.08.2022 – 31.07.2025

research institution

Technische Universität Darmstadt, Staatliche Materialprüfungsanstalt Darmstadt
Technische Universität Braunschweig, Institut für Oberflächentechnik

Abstract

Austenitic steels are often plasma-nitrided for increased wear protection, particularly in the food industry, medical technology and chemical plant engineering. Wear resistance is dominated by the thickness of the hard S phase formed during plasma nitriding. The steel used and the material structure significantly influence the thickness of the S-phase and the corrosion behavior under otherwise identical treatment conditions. Therefore, maintaining the corrosion resistance of plasma-nitrided steels remains problematic to this day and cannot be reproducibly guaranteed.
The aim is to determine the parameters for a plasma nitriding treatment that is individually optimised for the material and condition of austenitic steels, in order to reliably achieve the target values for wear protection whilst maintaining corrosion resistance.
The intended results hold the following innovation potential:
– Scientific and technical basis for the selection of treatment parameters during plasma nitriding
– Identification of limit values and parameter windows to ensure reproducible treatment results
– Economic advantages due to the material-adapted optimization of the treatment parameters as well as the reduction of damage or complaints
– Ecological advantages by ensuring or increasing the service life of components
– Gain in confidence through improved advice and product quality for reproducible achievement of the required corrosion and wear protection

Thus, the benefits and significance of the project are very high, especially for SMEs. The potential user group concerns the economic sectors 24 (metal production and processing); 28 (mechanical engineering), 29 (manufacture of motor vehicles and motor vehicle parts), 30 (other vehicle construction) as well as 20 (manufacture of chemical products) and 21 (manufacture of pharmaceutical products).

Poster – project results [PDF]

Final Report [PDF]

Publications:

[IOT-01] Development of a Model to Predict the Thickness of the s-Phase and Corrosion Behavior of Plasma-Nitrided Austenitic Steels, 66th Annual SVC Technical Conference, Washington D.C.

[IOT-02] Development of a model to predict the thickness of the s-phase and surface properties of plasma-nitrided austenitic steels, 13th Asian-European International Conference on Plasma Surface Engineer-ing (AEPSE), Busan

[IOT-03] Development of a model to predict the thickness of the s-phase and corrosion behavior of plasma-nitrided austenitic steels. 66th Annual Technical Conference Proceedings, Society of Vacuum Coaters

[IOT-04] P. M. Reinders, G. Bräuer, A model to predict the s-phase thickness and the change in corrosion behavior toward H2SO4 of 316L austenitic stainless steel after plasma nitriding, Surface and Coatings Technology 475 (2023) 130135.

[IOT-05] Effect of different plasma diffusion treatments on the surface properties of austenitic stainless steels, 19th plasma surface engineering (PSE), Erfurt

AiF-Nr. 22645 BG | EFDS-Nr. IGF-18/04

period: 01.10.2022 – 30.06.2025

Research centers
Fraunhofer-Institut für Werkzeugmaschinen und Umformtechnik IWU, Chemnitz
Fraunhofer-Institut für Schicht und Oberflächentechnik IST, Braunschweig

Abstract

Very high temperatures of 750 up to 1250 °C are required for forming high-strength Ti(Al) alloys, which severely limits the choice of suitable tool materials. An additional limitation occurs due to the adhesion tendency of titanium and titanium aluminides, which cause problems during forming. The “bonding” can cause damage to the components and the tool. In addition, material wear is promoted by the tendency to adhesion. Adhesions or residues from the previous forming process act as abrasive particles during the subsequent forming process, causing the components and tools to wear as a result of the high forces. The focus of this research proposal is the development of tool coatings for the isothermal forming of Ti(Al) alloys. Suitable tribological investigations and forming model tests are used to investigate, evaluate, further develop and optimize the tribological behavior of the surface layer after plasma boron and diffusion alloying of high-temperature molybdenum-based materials such as titanium-zirconium-molybdenum, molybdenum-hafnium-carbon or zirconium-hafnium-molybdenum compared with Ti(Al) alloys. The manufacturers of Ti(Al) alloys, manufacturers of special materials for tools, toolmakers specializing in the processing of special materials and manufacturers of special lubricants are closely associated with this topic. Tool coatings and diffusion treatments for high-temperature forming are absolutely new territory for coating companies and contract treaters. Since the expected results can be transferred to the wear protection of other machine elements and tools subject to high thermal loads, there is also great interest from this side. Overall, the aim is to serve a highly specialized market for high-end products with a high SME share and very good growth prospects.

Final Report TiAlHighEnd [PDF]

Publications

1. Demmler, M. (2025): Innovationen im Bereich der Werkzeugtechnik: Beschichtung, Tieftemperaturbehandlung und neueste Poliertechnologien. Fachtagung Stanzen und Umformen. Fraunhofer IWU. Chemnitz, 30.01.2025.
2. Demmler, M., Mejauschek,M. (2025): Tribologisch optimierte Werkzeugoberflächen für die Umformung von Ti(Al)-Legierungen bis zu 1.250°C. Fraunhofer-Institute. Chemnitz. Online verfügbar unter https://www.iwu.fraunhofer.de/de/projekte/tribologisch-optimierte-werkzeugoberflaechen.html.
3. Heidrich, J. (2024): Umformsysteme und Prüfmethoden für die Hochtemperaturumformung von Titan- und Molybdänlegierungen. Tagung Werkstoffprüfung. Krefeld, 05.12.2024.
4. Heidrich, J. (2025): Effekte einer zusätzlichen Tieftemperatur- und Randschichtbehandlung auf die Standzeit von Umform- und Stanzwerkzeugen. TAE Stanztagung. Ostfildern, 04.02.2025.
5. Mejauschek, M. (2023): Optimisation of high-temperature tool materials by diffusion processes. Dresden, 18.09.2023.
6. Templin, D. (2025): Development of Tribologically Optimized Tool Surfaces for the Cost-Efficient Forming of High-Strength Ti(Al) Alloys at 750–1250 °C. EFDS. Dresden, 15.10.2025.

AiF-Nr. 21807 N | EFDS-Nr. IGF-17/10

period: 01.05.2021 – 30.04.2024

Research institutions:
Technical University of Darmstadt, State Materials Testing Institute Darmstadt

Abstract:
Within the planned research project, fatigue stress is to be investigated with regard to the adhesion properties of functional coatings across the entire surface. For this purpose, application-relevant PVD coating systems (DLC, t aC, a C:H:Me) are to be selected in consultation with industry and samples or component sections are to be coated or made available. The necessary fatigue loading is to be generated by acoustic cavitation using ultrasonic coupled transducers (sonotrodes). The ASTM International (American Society for Testing and Materials) standard ASTM G32-16 provides a general test specification for tests on the ultrasonic coupling transducer, which is to be modified and further developed in the project. The test parameters (frequency, amplitude, test duration, medium, etc.) are varied with the aid of high-speed camera recordings in order to be able to evaluate the resulting stress in relation to the input variables in a spatially resolved manner. Based on the results, a comprehensive evaluation of the two-dimensional adhesion properties of the coatings relevant to the application as well as the suitability of the ultrasonic coupling oscillator method should be possible. The targeted parameter variations and the evaluation of the resulting interactions due to the changed stress combination form the basis of the qualifying further development of the cavitation investigation. The influence of the microstructure (e.g. columnar, amorphous structures, multilayer layers), as well as the possible developing crack growth within the coating are in the focus of the mechanistic description. The sonotrodes of the
ultrasonic coupling transducer are also to be adapted to specifically influence the cavitation in order to allow testing on simply contoured and curved functional surfaces for possible prenormative research.

Final Report KavErm [PDF]

Notice of result [PDF]

Poster [PDF]

Funding

The project is funded by the Federal Ministry for Economic Affairs and Climate Protection on the basis of a decision by the German Bundestag.

AiF-Nr. 22233 BR | EFDS Nr. IGF-17/17

project period: 01.04.2022 – 31.03.2024

research institution

Fraunhofer-Institut für Keramische Technologien und Systeme (IKTS), Dresden

Abstract

For several years, electromobility has been a topic that the automotive industry, the German government and the EU have been addressing and have formulated very ambitious goals. Current developments in electromobility, driven in particular by the automotive industry, require the development and production of reliable and durable batteries. To meet future demand, new, scalable process technologies for optimized semi-finished products and raw materials (e.g. active material powder) must be available in addition to production facilities for complete battery systems. Against this background, it is clear that manufacturers of coating equipment, service providers/contract coaters and suppliers of raw materials can participate precisely at the beginning of the battery production value chain. One problem with the current state of the art for lithium ion batteries is the use of active materials containing cobalt. Although cobalt can be partially extracted from recycling processes, open-pit mining of cobalt ores in the Democratic Republic of Congo is still the main resource in the extraction of this metal. For this reason, a major goal in this project is to develop a technology that avoids or greatly minimizes the use of cobalt or other critical raw materials, thereby contributing to sustainable technology development. The project will therefore use the Co-free high-voltage material LiNi0.5Mn1.5O4 as well as a high-nickel NCM with a low Co content (10%). The project aims to develop and evaluate coatings on active materials that will significantly facilitate and advance the use of Co-free or Co-low active materials. The main objectives of the project are to increase the energy density and service life of the batteries and to prevent degradation of the electrolyte by means of a suitable coating of the active material.

Poster [PDF]

Notice of result [PDF]

Publications

Vortrag | Titel: ALD for Lithium-Ion Batteries – Enhancing LIBs by Coating Cathode Active Material Powder via ALD, Autoren: M. Radehaus; PSE 2022, Erfurt, Veröffentlicht am: 14.09.2022

Poster | Titel: Functional coating of active material powders for enhancing Lithium-ion batteries, Autoren: M. Radehaus, J. P. Beaupain, E. Siebecke, H. Auer, M. Höhn; Konferenz/Tagung: V2023, Dresden, Veröffentlicht am: 19.-21.09.2023

Vortrag | Wet-Chemical Spray Drying of Coatings on Cathode Active Materials for Solid-State Batteries; Autoren: J.P. Beaupain, K. Wätzig, S. Yanev, H. Auer, K. Nikolowski, M. Partsch und M. Kusnezoff, Konferenz/Tagung: ICACC 2023 in Daytona, USA; Veröffentlicht am: 23.01.2023

Vortrag | Titel: Protective Coatings of Cathode Active Materials for Thiophosphate-based Solid-State Batteries; Autoren: J.P. Beaupain, K. Wätzig, S. Yanev, N. Zapp, H. Auer, K. Nikolowski, M. Partsch und M. Kusnezoff; Konferenz/Tagung: DKG-Tagung in Jena, Veröffentlicht am: 27.03.2023

Vortrag | Titel: Application of very thin coatings on different grades of particles by ALD; Autoren: M. Krug; Konferenz/Tagung: ALD for Industry 2024, Dresden; Veröffentlicht am: 13.03.2024

Poster | Titel: Rotating drum ALD – an alternative approach for ALD coating of powders, Autoren: M. Krug, M. Radehaus, M. Höhn, S. Yanev, P. Heizmann; Konferenz/Tagung: AVS ALD/ALE 2024 Helsinki; Veröffentlicht am: 06.08.2024

Artikel | Titel: Hochauflösende Charakterisierung von beschichteten Batteriepulvern; Autoren: S. Höhn, K. Gnauck, M. Höhn, J. P. Beaupain; Zeitschrift: IKTS Jahresbericht; Veröffentlicht am: 2024

Artikel | Titel: Funktionale Beschichtung von Batteriepulvern – Entwicklung ultradünner Schichten zur Erhöhung der Lebensdauer von Batterien; Autoren: M. Höhn, J. P. Beaupain, E. Siebecke, M. Krug, S. Höhn; Zeitschrift: Vakuum in Forschung und Praxis; Veröffentlicht am: Vol. 36 Nr. 3 Juli 2024 DOI:10.1002/vipr.202400816

Funding

The project is funded by the Federal Ministry for Economic Affairs and Climate Protection on the basis of a decision by the German Bundestag.

AiF-Nr. 21708 BR | EFDS-Nr. IGF-19/04

project period: 01.03.2021 – 28.02.2023

Research Institutes:
Fraunhofer-Institut für Organische Elektronik, Elektronenstrahl- und Plasmatechnik FEP
Fraunhofer-Institut für für Mikrostruktur von Werkstoffen und Systemen IMWS

Abstract:
Ultra-thin glasses (UTGs) with thicknesses of less than 100 μm are lightweight, flexible, and dimensionally stable, exhibiting low surface roughness and high thermal and mechanical strength. Compared to flexible organic materials, they are not permeable to water or oxygen. With the market launch of foldable displays, UTGs have recently entered mass production, but so far only in select high-priced products.
To establish UTGs as a flexible substrate material and alternative to polymer films, stable and reliable production processes must be developed. In these processes, mechanical failure of UTGs during the process has previously led to random, time-consuming, and costly production downtimes. To reduce the scrap rate, this project aims to gain fundamental insights into the mechanical behavior of UTGs during functionalization. This is particularly relevant because the mechanical properties change during the process due to separation, coating, and handling/transport of the UTGs. The following project objectives are the primary focus:
1. Determination of the initial strength of the UTG, particularly edge strength
2. Investigation of the influence of selected coating and separation processes on the mechanical properties
of the UTG, particularly edge strength and fatigue behavior
3. Correlation and evaluation of the results for two application cases: transparent electrode and anti-reflective coating system

The strength parameters obtained can be used directly for the dimensioning and design of plants along the entire value chain of UTG processing, especially by the SMEs involved in the PbA. Furthermore, based on the knowledge gained about the mechanical behavior of UTG, companies will be able to open up new fields of application for UTG and develop innovative products in a short time.

Final Report [PDF]
Poster [PDF]

Publication

Langgemach, W., Lorenz, G., Täschner, K. and Neidhardt, J. (2023), Optische Schichten und ihr Einfluss auf die Belastbarkeit flexibler Gläser. Vakuum in Forschung und Praxis, 35: 28-33. https://doi.org/10.1002/vipr.202300803

Langgemach, W., Rädlein, E. (2023), A new method – Evaluation of the influence of coatings on the strength and fatigue strength of flexible glass, submitted to Journal of Electronic Materials in 10/2023 (01/2024: under review).

Langgemach, W., Baumann, A., Ehrhardt, M., Preußner, T., Rädlein, E. (2023), The strength of uncoated and coated ultra-thin flexible glass under cyclic load, submitted to AIMS Materials Science in 12/2023 (01/2024: under review).

AiF-Nr. 20431 N | EFDS-Nr. IGF-16/13

project period: 01.09.2019 – 31.08.2022

research institute
Institut für Oberflächentechnik IOT der RWTH Aachen

Abstract

Energy-efficient mobility is necessary in order to avoid mobility restrictions in the future and to protect the environment. Increasing the efficiency of vehicle drive trains is of great importance here. The efficiency of a drivetrain is significantly influenced by friction in tribological contacts. Currently, the most important approach to reducing friction in the drivetrain is the use of lubricants, but this has technical, economic and ecological disadvantages depending on the type and the physical and chemical properties of the lubricant. In the field of electromobility, water-based lubricants are increasingly being used to reduce friction thanks to the low viscosity of the lubricants. An extension of the approach to holistic friction reduction is the elimination of conventional lubricants in the drivetrain, as internal friction in the lubricant as well as splashing and flexing can be eliminated. Dry running is therefore a promising concept for increasing the efficiency of drivetrains. However, its implementation requires an adaptation of the surface properties in tribological contact as a result of the changed load collective. For this reason, the proposed project will develop Cr-based nitride hard coatings with self-lubricating properties to reduce friction and wear in the dry running of drivetrain components such as joints. The nitride hard material matrix (Cr,Al)N is doped with Mo or W and S for this purpose. This enables the formation of the solid lubricants molybdenum or tungsten disulphide in tribological contact and thus the reduction of friction and wear in dry running. The layers are produced using the industrially relevant process of arc evaporation, which is being further developed as part of the project with regard to pulsed power supplies.

Publication

K. Bobzin, C. Kalscheuer, M.P. Möbius: News from Research, TRISTAN – Development of self-lubri-cating (Cr,Al)N+X:S coatings by pulsed arc PVD technology for dry-running powertrain components”, EFDS-Newsletter, 12/2022

K. Bobzin, C. Kalscheuer, M.P. Möbius: Neues aus der PVD-Technologie – Forscher am IOT der RWTH Aachen zeigen Vorteile gepulster Lichtbogenverdampfung“, Magazin für Oberflächentechnik, 02/2023

Final Report [PDF]

Poster [PDF]

AiF-Nr. 20963 BG | EFDS-Nr. IGF-18/05

project period: 01.01.2020 – 30.06.2022

research institute
Optotransmitter-Umweltschutz-Technologie e.V. (OUT)
Otto-von-Guericke-Universität

Abstract

The aim of the project is to develop reactive sputter deposition processes for the production of nitride semiconductor layers for optoelectronics and power electronics as well as for solar energy systems. Although basic processes are available, they have not yet been sufficiently studied for commercial exploitation. Thus, deposition rates are still low and plasma-induced damage to the film is not understood. Investigations into the doping of the layers and the controlled deposition of ternary layers are essential for the construction of components.
In order to achieve a better understanding of these processes and thus better control, the effects of plasma generation on the particle energies must be studied. For this purpose, investigations of the plasma and the coating process by means of plasma and coating diagnostics are planned in order to shed comprehensive light on the relationships between particle energy, both to favor coating growth and coating damage by high-energy particles. The dosage of the energy input via pulsed plasmas in combination with a high plasma density could be of fundamental importance here. The very short pulse durations (< 500 μs) in HIPIMS result in high ionization of the process gas and thus increased ion support. This could be the key to catching up to growth rates comparable to common GaN-based fabrication processes such as metal organic vapor phase deposition (MOVPE) (about 2 μm/h). For SMEs, reactive sputtering of nitride semiconductors is a cost-effective alternative to MOVPE because it has lower initial and ongoing costs. The sputtering technology to be developed for nitride semiconductors can provide the material basis for innovative products, especially for the development of new business areas in the fields of power electronics as well as hydrogen and fuel cell technology.

Final Report [PDF]

AiF-Nr. 21197 BR | EFDS-Nr. IGF-17/19

Laufzeit: 01.06.2020 – 31.05.2022

Research institutions:

• Fraunhofer-Institut für Keramische Technologien und Systeme IKTS, Dresden Klotzsche
• Helmholtz-Zentrum Dresden-Rossendorf e.V.
• Fraunhofer-Institut für Keramische Technologien und Systeme IKTS

abstract:

For defect testing on curved geometries with flexible sensors, so-called multi-channel flexible coil systems based on non-destructive eddy current testing are currently used. For technological reasons, these coil-based systems only work at higher test frequencies and therefore at low penetration depths. The industry’s demand for flexible eddy current arrays for sensitive applications with high penetration depths of 1.5mm to 10mm can therefore not be met at present. However, this is becoming ever greater, particularly with regard to free-form components produced using additive manufacturing and the increased use of geometrically complex fiber composite composites.
With conventional systems, the magnetic field sensitivity is reduced when the measuring frequency is reduced, as is the lateral resolution. GMR sensors as receiver systems, on the other hand, have the advantage of a frequency-independent magnetic field sensitivity and therefore offer the option of achieving a higher diagnostic depth with a consistently high spatial resolution. In addition, GMRs are predestined as array sensors due to their smaller dimensions and high manufacturing reproducibility. The approach pursued in this project also enables the construction of flexible GMR sensors for use on components with complex geometries.
The overall aim of the project is to develop an innovative flexible eddy current GMR sensor array with improved sensitivity, greater diagnostic penetration depth up to 10 mm with a spatial resolution of 0.5 mm to enable the mapping of electrically conductive components with complex shapes.
The resulting access to innovative testing methods and their manufacturing technologies gives SMEs important advantages when establishing their own products. Manufacturers of testing systems as well as testing service providers who expand their product portfolios with innovative solutions will benefit.ative solutions.

Final Report [PDF]

AiF-Nr. 20706 N | EFDS-Nr. IGF-17/08

AiF-Nr. 20662 BR | EFDS-Nr. IGF-17/05N

project period: 01.06.2019 – 31.05.2022

Research Institution:
Fraunhofer Institute for Material and Beam Technology IWS

Abstract

1 Research objective
• Development of a coating process for the targeted, variable adjustment of edge sharpness (edge ​​radius) on workpieces exclusively through a growing coating
• Further development of model concepts for layer growth on edges
• Evaluation of the durability of manufactured edges in model tests and their qualification for application-specific mechanical stress
• Creation and testing of demonstrators for various target applications and assessment of future industrial feasibility

2 Approach
Preliminary work has demonstrated that through targeted process control during coating (process gas pressure, evaporator current, electrical substrate bias, magnetic fields), in conjunction with an adapted coating system, it is possible to achieve reduced edge radii compared to the initial state. The dependencies and model concepts identified in this process will be utilized and further developed to achieve a targeted adjustment of the edge radius.
3 Desired Results
The outcome is a coating process that enables the targeted adjustment of the edge radius of coated substrates solely through the applied layer. Further Development Further development of model concepts for layer growth at edges is aimed for. By the end of the project, coated and tested demonstrator tools will be available, along with a comprehensive assessment of their industrial feasibility.
4 Benefits for SMEs
The new technology is expected to be applied to a variety of tools with defined edges. This will make them more efficient, durable, and reliable. Interested parties include tool and component manufacturers, coating service providers, and end users of the tools. Especially in the field of specialized tools and coatings, SMEs are predominantly active. Particularly for these companies, there are opportunities to strengthen current market positions and explore new markets.

Notice of result [PDF]

Final Report [PDF]

Poster [PDF]

AiF-Nr. 20231 N | EFDS-Nr. IGF-16/05

project period: 01.08.2019 – 30.04.2022

Research Institutions
Institute for Surface Technology (IOT) of RWTH Aachen University

Abstract

Due to global demands for CO2 reduction, the importance of lightweight design concepts, and consequently aluminum die casting, is increasing. An economical production requires an increase in the service life of die casting tools. Here, die casting cores are coming into focus due to the increased collective stresses they experience. The research objective is therefore to increase their service life in die casting. Based on the results of the previous project (AiF No.: 16471 N), promising methods of surface modification and coating processes will be utilized and further developed. The research focus is on the analysis and improvement of the thermal cycling resistance of the core tools. The influences of manufacturing processes such as hardening, plasma nitriding, shot peening, and coating on the residual stress profile in the tool edge zone will be quantified based on thermal cycling tests and industrial die casting trials. The hard coatings are produced using physical vapor deposition (PVD) via arc evaporation. In this process, innovative pulsed processes are implemented and analyzed using plasma diagnostics to enable the production of crystalline Al2O3 through improved process understanding. A large portion of German die casting machine manufacturers and operators, tool manufacturers, as well as PVD equipment manufacturers, contract coaters, and suppliers are small and medium-sized enterprises (SMEs) that benefit from application-oriented research results. The research project directly involves a manufacturer of release and lubricants for die casting, a provider of hardening shot peening services for tool pre-treatment, a developer of plasma power supply concepts, and a supplier of industrial power supplies. The relevance of the results applies to companies in the sectors of mechanical engineering, metal production, and metal processing, particularly for the manufacturing of metal products in the automotive industry.

Final Report [PDF]

Poster [PDF]

Final Report [PDF]

AiF-Nr. 20584 BG | EFDS-Nr. IGF-17/11

Laufzeit: 01.07.2019 – 31.12.2021

Research institutions:
Chemnitz University of Technology
University of Erlangen-Nuremberg

Abstract

Funktionsrelevante Bauteile, bspw. In sliding bearings and mechanical seals, they are subjected to application-specific loads. Due to a wide range of applications and production volumes in the millions, high demands are placed on production costs, sustainability, lifespan, and continual improvement of friction and wear behavior For heavily loaded sliding rings in axial mechanical seals, solutions made of hard metal and SiC exist, which are additionally coated with CVD diamond. This offers significant advantages, such as: compared to steel components with DLC coating that are also used in industry. While hard metal is significantly heavier and more expensive than steel, SiC sliding rings are highly prone to fracture. Thus, CVD diamond coatings on steel substrates come into focus, although they have not yet been economically realized. Among other factors, strong residual stresses develop in the diamond layer during cooling, which can lead to chipping, especially in thicker layers. There are approaches to reduce these stresses through defined microstructured surfaces and the resulting elastic deformation of the transition zone between the substrate and the coating. Therefore, the targeted design and creation of a fine shape during the machining of functional surfaces should enable an improvement in adhesion between the substrate and the coating. To achieve this, ultrasonic vibration-assisted turning will be utilized. As part of experimental investigations, CVD diamond coatings will be deposited on the defined microstructured surfaces of a selected steel material. The chemically necessary intermediate layers will be adapted to the boundary conditions. Subsequently, the diamond layer will undergo functionalization (smoothing of roughness and hydrophilization). Subsequently, the tribological performance of the application-specific modified test samples will be evaluated. Based on the findings obtained, test components from industrial partners will be modified accordingly and tested under their specific conditions.

Poster [PDF]

Final Report [PDF]

AiF-Nr. 20663 BR | EFDS-Nr. IGF-17/04

project period: 01.06.2019 – 31.05.2021

Research facility
Fraunhofer Institute for Applied Optics and Precision Engineering (IOF)

Abstract

New transparent polymers are an important foundation for the development of optical systems. Typically, the final functionality of the surfaces is achieved only through coatings. Specific properties of the polymers, such as low surface hardness, tendency for moisture and gas absorption, and susceptibility to UV degradation, affect the coatability, lifespan, and define the appropriate application range of the materials. The focus of the project is on new polymer materials that are already being requested for applications in camera systems, lighting optics, automotive construction, and medical technology. Die Materialien zeichnen sich teils durch eine ungewöhnlich hohe Brechzahl aus, eine andere Gruppe ist besonders transparent bis in den ultravioletten Spektralbereich. The aim of the project is to gain a fundamental scientific understanding of the interactions between plasma conditions typical for coatings and special polymer surfaces suitable for optics and to derive instructions for coating processes. Recommendations will be developed regarding advantageous application conditions for the polymers, while simultaneously highlighting their limitations. Optimized coating conditions will be tested and validated on optical model systems. It will be attempted to be cross-material. General conclusions will be drawn regarding the coatability of the investigated material classes and scientifically substantiated. SMEs in the fields of plastics technology, material development, and coating services can directly access this knowledge, effectively leverage the advantages of these novel polymer materials, and consider any limitations in manufacturing, coating, and application. Coated components made from the investigated materials will be used in numerous innovative products, such as in camera systems. for communication systems, as well as in the fields of medical technology, measurement technology, and lighting.

Final Report [PDF]

AiF-Nr. 20007 BG | EFDS-Nr. IGF-17/16

project period: 01.11.2018 – 30.04.2021

IGF project in cooperation between the Industrievereinigung für Lebensmitteltechnologie und Verpackung e.V. (IVLV) 100% and the Europäische Forschungsgesellschaft Dünne Schichten e.V. (EFDS) 0%.

Research Institutions:
Fraunhofer-Gesellschaft e.V., Fraunhofer Institute for Process Engineering and Packaging IVV
Leibniz Institute for Polymer Research Dresden e.V.
Institute for Corrosion Protection, Dresden GmbH

Project Leader:
Dr. rer. Nat. Matthias Reinelt
Dr. Anett Müller
Dipl.-Chem. Romy Regenspurger

CORNET | AiF-Nr. 230 EN | IGF-16/14

project period: 01.09.2018 – 28.02.2021

Forschungsstelle:
Fraunhofer IST, Braunschweig, Deutschland
University of Namur, Namur, Belgium
Materia Nova, Mons, Belgium

Abstract

Diamond-like carbon (DLC) coatings are used in a wide range of industrial applications due to their excellent properties, including low friction combined with high hardness, chemical resistance, and optical transparency. This includes the automotive industry, mechanical engineering, particularly cutting and forming tools. The DLC coating deposition occurs either via plasma-enhanced chemical vapor deposition (PECVD) or physical vapor deposition (PVD), including magnetron sputtering and ion source techniques.

The complex substrate geometries and arrangements commonly encountered in SMEs place high demands on the coating technology, as good coating thickness uniformity, high layer quality, and reproducibility are essential. To date, changes in substrate placement have regularly required complex run-in experiments, which significantly increase the overall coating costs.

In order to enable SMEs to achieve increased productivity and layer quality, DLCplus aims at an improved understanding of the mechanisms relevant to the coating process and layer growth. To achieve this goal, modeling of plasma and process dynamics as well as layer growth on an atomic scale will be combined. The intended cooperation between Materia Nova and the University of Namur in Belgium and Fraunhofer IST in Germany is necessary because it combines complementary competencies in both process and layer growth modeling and the available experimental process technology. The User Committee is made up of companies from the metalworking sector, automotive suppliers, plant manufacturers and coaters. The companies contribute with industrially relevant specifications regarding substrate geometry, process conditions and coating products, and they also provide substrates for test coating and reference samples.

Final Report [PDF]

AiF-Nr. 19885 BR | EFDS-Nr. IGF-16/03

project period: 01.01.2018 – 31.08.2020

Forschungsstellen/Projektleiter:
iba e.V., Heilbad Heiligenstadt
Leibniz-Institut für Plasmaforschung und Technologie e. V. INP, Greifswald

Abstract:
The research objective is the pre-competitive development of a plasma process for the deposition of adhesive, photocatalytically active TiO2 layers using high-performance pulse magnetron sputtering (HiPIMS) in combination with plasma-based ion implantation (PBII). The TiO2 layer is deposited using HiPIMS and will be technologically supplemented by ion implantation (PBII). This means (I) both a targeted doping of the TiO2 layers with foreign atoms and thus the excitation in the visible spectral range is possible and (II) the establishment of an antibacterial effect using the doping elements Cu, Ag or Zn. The layer adhesion is significantly increased by the combination process on the different substrates. Through targeted parameter variation, the layer properties desired by the user are adjusted by realizing an application-specific balance between photoinduced catalysis and photoinduced hydrophilicity. The requirements of potential users for the functional layer depend on the respective industry.
Implant manufacturers, for example, benefit from the photo-induced hydrophilicity of the coatings through increased wettability of the implant and thus improved healing. For users of sterile technology, the focus is on active disinfection of the surface through photo-induced catalysis. The food industry, in turn, hopes to shorten the required cleaning cycles and thus achieve considerable cost savings.

Final Report [PDF]

AiF-Nr. 19541 BR | EFDS-17/06

project period: 01.05.2017 – 31.10.2019

IGF project in cooperation between the Gesellschaft für Korrosionsschutz e.V. (GfKorr) 100% and the European Society of Thin Films (EFDS) 0%.

Research centers:
Institute for Corrosion Protection Dresden GmbH
Leibniz Institute for Polymer Research Dresden e.V.

Projektleiter:
Dr. Susanne Friedrich
Prof. Dr. Brigitte Voit

CORNET | AiF-Nr. 199 EN | IGF-16/04

project period: 01.09.2017 – 29.02.2020

Research centers
Fraunhofer IST, Braunschweig, Germany
Laser Zentrum Hannover, Hannover, Germany
Université de Namur, Namur, Belgium
CRM Group, Liège, Belgium

Abstract
The project created a common digital twin for PVD and PECVD coating processes that describes both the process and the layer growth dynamics. The complementary software tools existing at the project partners were further developed and validated demonstration cases were worked out at various coating plants. The advanced tools can be used for industrial simulation studies.

Publication

Final Report [PDF]

[Badorreck 2019]:
Badorreck, H.; Steinecke, M.; Jensen, L.; Ristau, D.; Jupé, M.; Müller, J.; Tonneau, R.; Moskovkin, P.; Lucas, S.; Pflug, A.; Grineviciūtė, L.; Selskis, A. & Tolenis, T.: Correlation of structural and optical properties using virtual materials analysis. In: Optics Express 27 (2019), Nr. 16, S. 22209

[Pflug 2019]:
Pflug, A.; Bruns, S.; Zickenrott, T.; Britze, C.; Vergöhl, M. & Kirschner, V.: Plasma and process modelling for PVD deposition onto moving 3D substrates. In: Proceedings of the 15^th ISSP., Kanazawa, JP (2019).

[Schwerdtner 2020]:
Schwerdtner, P.: Ortsaufgelöste Untersuchung der optischen Eigenschaften von Tantalpentoxid-Schichten im IBS-Beschichtungsverfahren, Bericht, Universität Hannover, Masterarbeit, Universität Hannover, 2020, S. 101

[Tonneau 2020]:
Tonneau, R.; Pflug, A. & Lucas, S.: Magnetron sputtering: determining scaling relations towards real power discharges using 3D Particle-In-Cell Monte Carlo models. In: Plasma Sources Science and Technology (2020)

[Tonneau 2021]:
Tonneau, R.; Moskovkin, P.; Muller, J.; Melzig, T.; Haye, E.; Konstantinidis, S.; Pflug, A. & Lucas, S.: Understanding the role of energetic particles during the growth of TiO2 thin films by reactive magnetron sputtering through multi-scale Monte Carlo simulations and experimental deposition. In: Journal of Physics D: Applied Physics 54 (2021), Nr. 15, S. 155203

CORNET | AiF-Nr. 185 EBR | IGF-15/07

project period: 01.02.2017 – 31.12.2019

Research institutions
Dipl.-Ing. Matthias Demmler, Fraunhofer IWU, Chemnitz, Germany Innovation and Development Promotion Center – coordination of Metal Processing Cluster, Blatystok, Poland Institute of Precision Mechanics, Warsaw, Poland Rzeszow University of Technology, Rzeszow, Poland Moravian-Silesian Automotive Cluster c.a., Ostrava, Czech Republic COMTES FHT a.s., Dobrany, Czech Republic

Documents:

Final Report [PDF]

Poster [PDF]

CORNET | AiF-Nr. 163 EBG | EFDS-Nr. IGF-15/05

project period: 01.06.2016 – 30.08.2018

IGF project in cooperation between Forschungsgesellschaft Kunststoffe e.V. (FGK) 100% and European Society of Thin Films (EFDS) 0%.

Forschungsstelle:
Fraunhofer IWU, Chemnitz, Deutschland
Plastikarsky klastr, Polen
Univerzita Tomáše Bati ve Zlíně, Polen

Accordion Contents