Projects

OPPIK

2021

Research and development of heat treatment of bearings from nanostructural material

FW03010108, 1. 1. 2021 31. 12. 2024

Annotation: The main goal of the project is to ensure the global competitiveness of bearings manufactured by the ZKL Group in the long term and to gain new customers for these products with higher added value or possibly increase sales of products in existing markets. Therefore, the project is focused on research and development of new sophisticated production technology of individual bearing components, i.e. rings and rolling elements of axle cylindrical roller bearings in order to significantly increase their overall utility value through a fundamental innovation of heat treatment technology based on advanced isothermal process, which results in very fine nanobainitic structure of bearing steel, which ensures the fulfilment of high requirements for bearing properties by the customer's wishes.

2020

Development of high strength and low young’s modulus, bioactive and antibacterial porous titanium structures for orthopaedic implants

LTAIN19112, 1. 1. 2020–31. 12. 2022

Annotation: The aim of this research is to develop high strength, low young’s modulus, bioactive and antibacterial commercially pure titanium (Cp-Ti) scaffolds with different porosity levels by DIW and subsequent coating by PEO-EPD process. Specific objetives are: 1. To optimize the rheological properties of the titanium ink for DIW. 2. To produce titanium scaffolds with 30 to 50 % porosity and pore size between 200 and 500 m. 3. To remove the organic binder used for DIW without the chemical contamination of titanium. 4. To optimize the sintering processes of titanium scaffolds to mimic the mechanical performance and density of human bone. 5. To produce adherent nanocrystalline titania-hydroxyapatite (HA) nano composite coatings on porous Titanium scaffolds by PEO coupled EPD processes. 6. To study the corrosion resistence and bioaktivity of teh coatings. 7. To access the cytocompatibility of the coated titanium scaffolds. 8. To demonstrate in vitro the bacterial infection resistance of the surface modified titanium scaffolds.

New materials for emerging energy technologies

LTC20068, 15. 5. 2020–26. 2. 2023

Annotation: The project aim is an extensive research on the employment of mechanochemical synthetic approach for the production of metal matrix nanocomposite powders based on Mo and reinforced with rare-earths oxide phases for reduction of ductile-to-brittle transition temperature and improvement of high temperature oxidation behaviour. This aim will be achieved by applying solid-solid (ex-situ) and liquid-solid (in-situ) composite powder synthetic strategies, utilizing the high energy kinetic milling, reactive kinetic milling, mechanochemistry and chemistry. In the ex-situ study the ultrafine powders of rare-earths oxide phases (mainly based on La, Gd, and Ce oxides and zirconates) will be synthetized via sol-gel techniques or mechanochemical syntheses, and in a secondary phase they will be milled with the commercially available Mo metal powders using high-energy ball milling. The role of milled powder chemistry as well as the effects of technological parameters, i.e. milling speed, milling time, milling temperature, milling atmosphere, milling media, ball-to-powder ratio and process control agents on reduction of powder particle size, rare-earth oxide or zirconates particle distribution at the metal grain boundaries, and its influence on alloying or phase transformation will be investigated. The in-situ study will focus on processing, reaction mechanisms and technological parameters with the aim to obtain composite reinforcement with rare-earth oxide/zirconate phases directly from the reagents mixed with Mo metal powders in high-energy ball mill. Both powders, produced by ex-situ and in-situ methods will be studied by the means of available techniques widely used in materials science.

2019

Research and development of single-purpose machine for machining of complex-shape ceramic grinding tools utilized in automotive and aviation industry

FV40099, 1. 4. 2019–31. 12. 2020

Annotation: The project focuses on the development of specific single-purpose machining centre dedicated to processing and monitoring of highly accurate and complex-shape grinding tools made from modern abrasive materials and utilized especially in automotive and aviation industries, where high demands on quality and dimension control of grinding tools are of critical importance. New machining centre will have modern control elements linked to automatic evaluation of dimensions after the machining. The current machining process in the applicant’s company is carried out by a number of individual machines, which are used for the final machining of grinding tools. Up-to-date machining of complex grinding tools is accomplished utilizing at least four separate machines, where individual surfaces of the grinding tool are processed. However, this method of manufacturing of geometrically complex grinding tools is ineffective in terms of expended and personal costs, time and energy. For these reasons, the project aims on automation of whole machining process. Furthermore, project will cover not only the development of the machining centre itself, but also the automation of the input and output control mechanisms, which will evaluate the technical parameters and materials of the grinding tools. The project will be solved in the production area of Best – Business company, which is a traditional producer of abrasive tools, materials and heat-resistant products, in partnership with the Central European Institute of Technology – Brno University of Technology, and the Center of Progressive Technologies. New single-purpose machining centre will have a major impact on the quality, precision, reproducibility and final price of the highly accurate and complex-shape grinding tools, and thus will significantly strengthen the competitiveness of the Czech medium-sized company of project coordinator at the national and international markets.

Research and development of a special type of abrasives for grinding ring bearings with an emphasis on complying with the integrity of orbital grinding patterns

FV10817, 1. 9. 2019–31. 8. 2020

Annotation: The submitted project continues the applicant’s development activities and sets to develop a new type of grinding tools for ring bearings with an emphasis on complying with the integrity orbital grinding patterns, while researching special grinding materials and refining them, chemical additives and advanced technological manufacturing procedures for totally new prototypes of efficient grinding tools, also usable for other applications than for grinding ring bearings. The assignment of this project quite unique, as it researchers and develops new surfaces, chemical additives, grinding materials and advanced technologies for manufacturing grinding tools while implementing nanotechnologies for verifying advanced material and manufacturing technologies with the LIBS method. The realization of the project pushes the limitations of research and development to the top-level within the European Union, which will create entirely new properties of the resulting products, helping users of grinding tools increase the level of their products and improve work and environmental conditions of manufacturing itself. The purpose of the project is to develop and realize new highly efficient and environmentally friendly technologies while using the most modern and advanced materials and production technologies. The realization of this project will increase the competitiveness and the growth of the applicant – coordinator, further developing innovations, which meet requirements of European and world markets, by utilizing findings gained from the borders of human knowledge.

2018

Unconventional technology of production of magnesium alloy castings by the method of precise casting and controlled melt solidification in ceramic form

FV30305, 1. 1. 2018–31. 12. 2021

Annotation: The project is focused on a research and a development of unconventional casting technology of high-quality, lightweight and tough castings of magnesium alloys by method, which is still unused in CZ and EU, of precise casting and controlled melt solidification in a ceramic form. Thus, the main aim is a development of own unconventional technology for production of precise castings from magnesium alloys for aircraft and automotive industries, optical devices, components of medical aids, components for hobby applications and further on for castings of components used for production of very shape-complex biodegradable implants in order to achieve quality and parameters comparable to the world’s leading manufacturers. Subject of application research and experimental development will be to achieve by this way the desired utility properties of magnesium alloys based on AZ91 which in current global market find significant use in, for example, aircraft and optical industries and further on in shape-complex castings for biodegradable applications from magnesium alloy WE43 (containing Y, KVZ and Zr) which is used for its low corrosion resistance (a disadvantage in engineering applications). Their use in production of biodegradable implants is allowed by their low corrosion resistance, suitable mechanical properties and osteoinductivity. The results achieved in the partial stages of the project solution will be used with feedback for the subsequent modification of the developed technology from the test samples to the actual production of the shape-complex real castings. Attention will be also paid to minimization of casting defects, increasing the utility properties of magnesium alloys and optimization of a process of their subsequent thermal or thermo-mechanical treatment.

Research and development of advanced types of bonds for special grinding tools

FV30335, 1. 4. 2018–30. 4. 2021

Annotation: The proposed project aims to develop new chemical additives and binders that will be examined in the context of rubber and Bakelite binders for new prototypes of powerful grinding tools when introducing production of necessary chemicals. The project will be implemented in the manufacturing area of ​​the company Best - Business, a.s., which is a traditional manufacturer of grinding tools and materials in the Czech Republic and next in the centre of excellence CEITEC VUT Brno and the Centre of advanced technologies and Zkl, a.s.. Entering this project is quite unique because it is the research and development of new coatings, chemical additives, to the rubber and Bakelite binder with using of advanced technological processes for making abrasive tools using nanotechnology in the verification of advanced materials and manufacturing technologies. The project implementation is pushing the boundaries of research and development at the top level in the European Union and thus will be an entirely new utility properties of the resulting products help users move abrasives technological level of its products and improve labour, environmental conditions of the production itself. The project is the development and implementation of new, highly efficient and environmentally safe technologies using the latest advanced materials and manufacturing technologies. The realization of this project will be strengthened the competitiveness and growth of the companys bid - Coordinator, further developing innovations that meet the needs of European and world markets by using knowledge obtained at the frontier of human knowledge.

2017

Structural biodebradable implants processing by means of direct metal laser sintering

FV20232, 1. 7. 2017–30. 6. 2021

Annotation: The main objective of the project is development and production of innovative biodegradable porous bone void fillers. Material used for production of such implants will be magnesium alloy WE43, which exhibits good biocompatibility. Mechanical properties of the alloy are close to those of bone tissue and implants from such alloy can therefore provide sufficient support to the healing tissue without undesirable stress shielding effect. Implants from such alloy also exhibit osteoinductive properties and its degradation promotes bone tissue healing process. The implant is gradually resorbed by organism during healing process providing support. After the healing process ends, no metal residues are left in the body and there is no need for costly operation for implant removal. Application of biodegradable implants is therefore less invasive, comparing to commonly used bioinert materials. For cell adhesion to the implant, not only implant material type or its surface treatment is important, but also state of the implant surface. Therefore, bulk and porous implants as well as implants with bulk core and porous surface layer will be tested. For the production of implants, selective laser melting method will be used. Such progressive method allows not only production of complicated shapes but also control of porosity of final component. Alternatively, CaP based surface treatments and their influence on corrosion properties and biocompatibility of the whole implant will be tested.

2016

Research and development of coatings from abradable materials for turboprop engine thermodynamic efficiency improvement

FV10211, 1. 1. 2016–31. 12. 2018

Annotation: The goal of the project is research and development of thermal coating´s advanced materials and technologies for application of coatings in a cold compressor part and hot turbine part of an aircraft turboprops engine H80 and its derivative versions, with the purpose to reach a decrease of pressure loss and to increase engine thermal efficiency. Decrease of pressure losses will be reached by applying abradable coatings´ material in the area of radial clearance between the rotor and stator part of the engine. Providing the current operation conditions of the turboprops engine will remain, it is expected that reaching the goals of the project by applying advanced material of the abradable coatings and by superposition of the proposed solution in the cold as well as hot part of the engine will enable to decrease thermal load by more than 18°C and reduce the fuel consumption by up to 5,5 g / kW / h (by cca 1,5 %), which also directly corresponds with extension of life of coated components and reduction of emission of undesired greenhouse gases. Besides the commercially available materials used for similar applications in energy, partial goal of the project will also be a proposal for new material systems and specific testing methods of these surface treatments, which could be used for these applications in aviation.

Combined Plasma Source Technology for Processing of Advanced Coatings

FV10477, 1. 7. 2016–30. 6. 2019

Annotation: The main goal of the project is the development and construction of the hybrid unit that will combine the two major current coating technologies of vacuum plasma spraying and physical vapor deposition or other sputterig method. The device is designed for application of advanced multilayer and gradient coating systems with improved properties that could be achieved either via sequential deposition or by codeposition. The combination of both technologies allows to exploit the advantages of each method, in particular high deposition rates and the versatility of plasma-spraying, which permits the coating microstructure to be tailored for specific applications, and generally superior physical properties of coatings produced by physical vapor deposition. Moreover, the availability of both technologies within a single unit removes the need for any extensive manipulation with coated components.

2015

Research center of surface treatment

TE02000011, 1. 1. 2015–31. 12. 2019

Annotation: The main goal of planned center is focused on the application of new or modified polymers and suitable organic or inorganic compounds to the protection and modifications of various types of surfaces, which will bring new properties and opportunities for their practical utilization: 1) Development of coatings with extended corrosion resistance, low VOC with customs tailored functionality (for machinery, aircraft industry, civil engineering and power engineering), both water and solvent borne. As an example can serve new coating system with special functionalities optimized for Middle Europe climatic conditions. This point will solve both stable and temporary corrosion protection. 2) Development of industrial quick drying paint with improved weatherability. 3) Coatings for fuel integral tanks for aircrafts. 4) Fireproof coatings for aircraft interiors. 5) Coating with improved biofouling properties (built-in biocides, plasma treatment), especially for power and civil engineering (e.g. cooling towers protection). 6) Improved coatings containing polymer binders with structured polymers, microgels or nanoparticles. 7) Coatings responding to environment changes. 8) Electrically conductive coatings. 9) Coating with low surface energy or modified surface with low surface tension. 10) Surface modifications by e.g. plasma treatment to reach the optimum coating properties. Hydrophilization or hydrophobization of coating or substrate surfaces, improvement of coating adhesion between individual layers, plasma assisted curing, surface passivation. 11) Harmonization of newly developed coatings and their disposals with all existing or intended environmental requirements. Optimization of production process and application by ensuring environmental friendliness and safety.

Plasma deposition, microstructural and thermo-mechanical stability of environmental barrier coatings

GA15-20991S, 1. 1. 2015–31. 12. 2017

Annotation: The proposed project is directed to the preparation of advanced environmental barriers operating in oxidizing and corrosion atmosphere under variable loading at high temperature. A bond metallic coat CoNiCrAlY and an environmental barrier top coat of the BMAS type protecting the coating system against the frequent foreign object damage will be deposited on the surface of cast nickel base superalloy Inconel 713LC using air plasma spraying. Thermal barrier coating based on ZrO2-Y2O3 will be alternatively deposited between the bond and top coats. Thermo-mechanical and microstructural stability of these systems will be studied with experimental tests (thermal exposure, high temperature low cycle fatigue, its interaction with creep and thermo-mechanical fatigue) and analytical methods (microstructure, chemical and phase composition) that make possible to acquire lifetime data of the coatings in conditions close to their application and to identify mechanisms leading to their degradation. The results obtained will be also compared with properties and behaviour of uncoated material.

2013

Research into and development of high-speed surface machining technology for hard-surface coatings prepared by thermal spraying

TA03010517, 19. 2. 2013–31. 12. 2015

Annotation: The key areas in the solution of the proposed project are the optimization of parameters of plasma-sprayed high-quality ceramic and cermet coatings and applied research into and experimental development of a device allowing high-speed mechanical machining of surfaces of piston rods of extreme lengths while reducing the enormous wear of cutting tools. The effort will be devoted to achieving minimum rod runout gauge and minimum surface roughness of coatings optimized for subsequent usage in hydraulic systems.

Research of advanced lightweight alloys for engineering applications

TA03010188, 1. 5. 2013–31. 12. 2016

Annotation: The project is focused on research and development of unconventional methods of controlled cooling of high-quality, light and tough casting of aluminum alloys produced by precision casting, with solidification via immersing the mould with the melt into the cooling mediums. The results will be continuously applied in the modification of the production technology and in the high-strength aluminum castings production. Furthermore, new magnesium alloy will be developed with better mechanical properties comparing to AZ91 magnesium alloy. Structure, physical and mechanical properties will be studied and further will be verified the possibility of using this alloy for some current products from the range of Alucast company. Suitable heat and thermomechanicaltreatment will be found that will further improve the properties of light-alloy castings. The structural, mechanical and physical characteristics of thus treated alloys will be investigated.