Metallic and Ceramic Materials

Treatment of the main problems and limitations currently identified in the field of PVD (Physical Vapor Deposition) coating technology to improve the mechanical performance and durability of components and tools used mainly in the metal-mechanic sector. The project develops an innovative PVD hard coating technology that allows high thicknesses of up to 100 microns to be achieved at high deposition rates (20 microns/hour), enabling its application in new industrial sectors that were previously unapproachable. This innovation constitutes a real, technically, economically and environmentally viable alternative to other coating technologies that, like hexavalent hard chromate, present serious [...]

FormPlate seeks to optimise the energy efficiency, cost and durability of metallic bipolar plates, a key component to guarantee the energy efficiency of proton exchange membrane (PEM) hydrogen fuel cells for application in the automotive sector. The technological innovation of the project is based on: New geometric plate designs by Finite Element Method (FEM) and Computational Fluid Dynamics (CFD) simulations. Development and improvement of plate manufacturing techniques. Implementation of alternative metallic materials to reduce the cost and weight of the plates. Development of protective, electrically conductive and corrosion-resistant coatings. The energy transition towards electromobility and sustainability [...]

Collaborative research to find solutions in the functionalisation of surfaces. The INFUNDA project is a collaborative research business initiative carried out by seven companies (KOSTAL, WALTERPACK, TOUS, MAIER, INECFI, FLUBETECH and GOIZPER), two of which are SMEs (INECFI and FLUBETECH), which have come together to combine their knowledge and provide solutions in the functionalisation of surfaces, both in plastic and metal components. INFUNDA is part of the latest generation of innovative enabling technologies that are at a basic level of maturity, identified by their high application potential, giving companies a differential position by giving way to [...]

Solution to increase the useful life and quality of high pressure casting molds (HPDC). Project INNOCAST aims at developing an innovative physical vapor deposition (PVD) coating concept, based on nanostructured morphology to generate a complex layer of surface oxides to greatly reduce wettability and attack by molten aluminium on die casting tools. The project also investigates the use of ion implantation to modify the PVD coating, a highly innovative concept in the metal-mechanic sector that will allow the creation of phases with self-lubricating and wear-resistant properties. To validate the performance of these new solutions, a pilot [...]

Flexible and hybrid manufacturing of green aluminium to produce tailored vehicle adaptive crash-tolerant structures. The Flexcrash project, coordinated by Eurecat, is developing a flexible and hybrid manufacturing technology using aluminium alloys and based on applying surface patterns by additive manufacturing onto preformed parts. In the last years, the automotive industry has made important efforts focused on lightweight construction to meet the stringent Greenhouse Gas Emission limits and increase passenger safety. However, both aspects are counteracting because we need heavier structures to improve passenger protection, but heavier vehicles also produce more severe crashes. In this sense, the [...]

PRISTINE in a nutshell Removing Contaminants of Emerging Concern (CECs) from water streams thanks to the PRISTINE Integrated Solution ABOUT THE PROJECT LIFE PRISTINE project aims to develop the PRISTINE Integrated Solution to remove Contaminants of Emerging Concern (CECs) from water streams. The PRISTINE Integrated Solution will be adaptable on a case-by-case basis for drinking water (DW), to protect humans from CECs, and for wastewater (WW), to protect the environment and remove these contaminants from the water cycle. LIFE PRISTINE will focus on [...]

Development and testing of fasteners able to withstand high applied stresses under harsh environmental conditions typical of large offshore wind turbines. The HELIX project provided lower cost (up to 20% reduction), high corrosion resistant (a minimum of 25 service years), high strength steel (10.9 and 12.9 grades) and high diameter (≥ M64) fasteners to the offshore wind industry to support the ever-increasing size of wind turbines, leading to higher productivity. HELIX used advanced characterisation and traditional techniques under both atmospheric and immersion conditions to advance in the knowledge of hydrogen absorption in high strength steels under [...]

Valorisation, dissemination and awareness about the concept of fracture toughness, as well as its extension to other applications in the steel sector and to other industries working with Advanced High-Strength Steels (AHSS). The ToughSteel project involves and engages the main stakeholders around the steel sector with the objective to promote, disseminate and transfer the know-how acquired in previous projects about the use of fracture toughness as a tool to address cracking problems in forming and in-service performance of AHSS. The main objectives of the project are: Collect, organize and analyse the fracture toughness data measurements (from previous [...]

Development of an alternative source of Critical Raw Materials (CRM) on Aluminium Alloys for electrical vehicles. The SALEMA project, coordinated by Eurecat, proposes a circular economy model using scrap metal as an alternative source of CRM and the substitution of them for commonly available alloying elements. The project is addressing in a coordinated and cooperative manner the key challenges in the different levels of the value chain: Improving scrap classification and sorting systems to turn scrap into a valuable raw material Demonstrating the feasibility to substitute CRMs in alloying systems Developing recycled aluminium alloys with improved [...]

High-performance steels addressed to electric mobility sector obtained through the use of recycled material. Currently, the European industry and mobility is facing a two-pronged challenge: the need of obtaining materials with increasing performance and cost competitiveness, while at the same time, reducing their ecological footprint and foreign dependency. Affordable and indefinitely recyclable, high performance steel is an attractive solution to this conundrum. The ReMove project aims to obtain two advanced materials needed for electric mobility sector through material recycling routes: Boron steel for press hardening, a high-performance structural material which has become the current standard in [...]

Recovery of titanium sheet waste to manufacture titanium metal powder through atomisation. The VARTIP project valorises titanium sheet metal waste with the objective to manufacture high-value titanium powder and promote its future commercialisation. In this sense, VARTIP is developing a centrifugal atomisation technology for high melting point metals, which will allow to manufacture spherical powders, an indispensable characteristic to accomplish in most of powder applications. The valorisation process consists in a direct transformation of the sheet scrap into powder by atomisation, without intermediate stages, which makes it a more energy-efficient and economically advantageous process. Eurecat participates [...]

Design, manufacturing and validation of the next generation of battery packs for the automotive mass-market. The MARBEL project develops an innovative and competitive lightweight battery with increased energy density and shorter recharging times with the objective to accelerate the mass market take-up of electric vehicles. The project innovation is based on the following main pillars: Advanced battery packaging using a Design for Assembly (DfA) and Disassembly (DfD) methodology. Lightweight and sustainable Battery Packaging. Solutions and processes for the sustainable dismantling and 2nd life Flexible advanced battery management systems. Ultra-Fast Charging strategies and enhanced thermal management Procedures for [...]

Development of a complex material model for press hardening of steel, covering mechanical, thermal and metallurgical factors to generate an accurate prediction of the final behaviour of the material. The MiPre project has the objective to improve the accuracy of metallurgical and mechanical modelling to predict material properties in press hardening. Together with improvements in sensoring and process control, these advances will allow a further level of microstructural tailoring, leading to components with locally optimized properties. The use of new press hardening technologies in combination with high strength metallurgical concepts is known to be a competitive [...]

Production of metal glass powder through the development of a new centrifugal atomization technology. The GLASCENT project aims to develop a new technology for producing glass metallic powders. Metallic glasses are metals with an amorphous microstructure that are obtained by rapid cooling techniques. These advanced materials have a huge interest in many fields of engineering due to their combination of properties and characteristics such as a high hardness, a high yield strength and a high fracture toughness or corrosion resistance. The Unit of Metallic and Ceramic Materials of Eurecat participates in the GLASCENT project in the [...]

Control of risk for hydrogen embrittlement (HE) in steels for automotive applications. The CRYSTAL project, coordinated by Eurecat, aims to reduce the hydrogen embrittlement risk in high strength steel parts for the automotive industry. The project will use a novel solid-state gas sensor to quantitatively measure in-situ the hydrogen absorbed during the production of steel parts and during their service life. On the other hand, the CRYSTAL project will also define and determine the best methodology to evaluate HE during steel production and life span of the components. To determine which is the test that allows [...]