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HYBRID MATERIALS. 2014-2017. the Program FINAL REPORT 5/2017 PUBLICATIONS PUBLICATIONS DIMECC SERIES NO.18 HYBRIDS – HYBRID MATERIALS 2014 – 2017 9 789522 381958 FINAL REPORT 5/2017 HYBRIDS – HYBRID MATERIALS DIMECC PUBLICATIONS SERIESNO.18 2014 – 2017 All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior permission of DIMECC Oy. Publisher DIMECC Oy Korkeakoulunkatu 7 33720 Tampere Finland www.dimecc.com ISBN 978-952-238-195-8 ISBN 978-952-238-196-5 (pdf) DIMECC Publication series ISSN 2342-2696 (online) © DIMECC Oy Graphic design and layout: Public Design Oy English language editor: Semantix Oy Printed in Finland: Grano Oy, Tampere, 2017 2 FINAL REPORT 5/2017 CONTENTS DIMECC FOREWORDS Essi Huttu: GreaterThan the Sum of the Parts ......................................................................................................... 4 PROGRAM MANAGER'S REVIEW Markku Heino: Application-driven Digitalized Development of Knowledge-intensive Materials Solutions........................................................................................................................................................................... 5 INDUSTRIAL REVIEW Heikki Kettunen: Strategic Research – a Natural Connection Between Industry and Academia ....................................................................................................................................................................................... 8 RESEARCH INSTITUTE‘S REVIEW Erkki Levänen: Hybridization .................................................................................................................................................. 10 DIMECC HYBRIDS Program Key Characteristics .............................................................................................................. 12 1 MULTIFUNCTIONAL THIN COATINGS .................................................................................................................................. 16 Combining performance with appearance in thin coatings ................................................................................... 16 2 MULTIFUNCTIONAL THICK COATINGS AND COMPOSITES .......................................................................... 28 Advanced materials processing creates multifunctional properties and performance to thick coatings and composites .................................................................................................... 28 3 LIGHT MULTIFUNCTIONAL HYBRID STRUCTURES .............................................................................................. 39 Damage detection and intelligent sensing ............................................................................................................................ 39 New materials for noise and vibration control ................................................................................................................. 50 Controlling the interfacial properties in hybrid materials....................................................................................... 63 Transition towards Circular Economy – life cycle perspective in material development ........... 73 4 POLYMER MULTIFUNCTIONAL SLIDING MATERIALS ......................................................................................... 80 High performance for industrial components through polymer materials in oil-free contacts ..................................................................................................................................................................................... 80 Lubricated hybrid sliding bearings for demanding operational conditions............................................. 87 5 FUNDAMENTALS AND MODELING ......................................................................................................................................... 98 Digitalizing materials development ............................................................................................................................................ 98 DIMECC Breakthrough materials doctoral school .......................................................................................................... 108 List of publications .................................................................................................................................................................................. 114 3 DIMECC FOREWORDS Greater Than the Sum of the Parts any industrial applications in various fields require material property combinations that cannot be achieved using conven- M tional materials. Hybrid materials consist of at least two compo- nents acting in concert to make a correlated material that intensifies the advantages of the original constituents, compensates for the disadvan- tages, and even shows new exceptional properties. What is sought is an outcome that is greater than the sum of the parts. The DIMECC HYBRIDS program was designed to create new capabili- ties enabling the combination and use of common engineering materials in an innovative way. The mission of the program was to build a unique technology platform and world-class competencies, such as engineer- ing processes for material selection and product design, design-related material property data for hybrid materials, and computational tools for hybrid material multiscale modeling and simulation. This hybrid materi- al excellence created in the DIMECC HYDRIDS program provides key in- dustrial advantages and key enabling technologies to apply advanced materials effectively in future applications. The same principle also applies to innovation. In today's society, inno- vation and disruption cannot be achieved by one organization on its own. Instead, co-creation is needed, enabling systemic change and the inte- gration of capabilities of multiple actors. Effective co-creation requires management excellence. DIMECC has created a unique world-class in- novation platform and related processes, bringing actors together, facil- itating cooperation toward a common goal, and making the most of all of our work. The best examples of excellent co-creation in one of DIMECC’s thematic focus areas, materials, can be seen in this final publication. I warmly thank the HYBRIDS consor- tium for their great collaboration. In particular, I would like to acknowledge the program management team, Markku Heino and Vilja Vara, for their effort in leading the program and mastering the collaboration among the participants. I also thank Tekes for the public funding needed in such a huge effort. We in DIMECC believe collaboration is the key to the Essi Huttu success and competitiveness of Finnish industry. Through Vice President, the DIMECC co-creation platform, our aim is to facilitate Co-creation co-creation between multiple actors, resulting in cooper- DIMECC Ltd ation that is greater than the sum of the parts! 4 PROGRAM MANAGER'S REVIEW Application-driven Digitalized Development of Knowledge-intensive Materials Solutions he DIMECC Hybrid Materials (HYBRIDS) program set the ambitious aim of renewing and strengthening the Finnish manufacturing in- T dustry by creating and effectively running a unique multidisci- plinary knowledge platform for advanced materials solutions. The pro- gram has focused on solving fundamental challenges in the develop- ment and industrial application of multi-materials, such as specific com- posites, coatings, and layered structures, to create unique property com- binations that conventional materials do not possess. The goal has been to create both novel multi-disciplinary competencies and value-added, hard-to-copy hybrid material solutions that meet tough customer and application requirements, bringing a crucial competitive edge for Finnish companies in the global market. The identified critical materials challenges have been solved through intensive joint R&D work in four industry-led project entities, focusing on new coating materials and technologies, multifunctional composite and hybrid structures, and novel tribological solutions for selected industrial applications. As a result, a variety of important solutions have been devel- oped, such as new wear- and corrosion-resistant, non-sticking, energy- absorbing/reflecting coatings, functional lightweight composites, hy- brid structures for sensing and monitoring, or novel slide bearings and tribological contacts improving significantly the energy efficiency and operational reliability of machines and equipment. The key issue in all these has been well-defined research problems based on real applica- tion needs, and ambitious tackling of the complex phenomena through sharp multi-disciplinary experimental research and modeling. The cross-cutting fifth project (FUNMODE; Fundamentals and model- ing) has been the key tool to build the required comprehensive under- standing of critical fundamental phenomena, and to develop the model- ing and simulation expertise in material properties, based on real-life in- dustrial challenges. In this, we have built comprehensive world-class ca- pabilities in so-called Integrated Computational Materials Engineering (ICME), boosting the implementation of modern, experimental and multi- scale modeling tools to solve real industrial problems effectively. The dig- italized materials development enables shortening development time significantly, in many cases to a half. Providing solid understanding of complex phenomena,
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