Future tasks in many different fields of academia and industry are directed towards an emission reduction of greenhouse gases and a sustainable usage of resources in general. This endeavor is often referred to a net zero carbon footprint and a highly complex interaction of various factors. Despite the huge technological puzzle effecting this aim, every contribution is needed. As surface science and engineering obtains a highly interdisciplinary character, it can give in various industrial fields – starting from medical applications, semiconductor industry, automotive, aviation as well as energy production – a decisive impact for future enhancements. Especially, physical vapor deposition (PVD) based synthesis techniques constitute a key-technology for the deposition of thin film materials based on tremendous design capabilities. Therefore, this Christian Doppler Laboratory for Surface Engineering of high-performance Components aims for the exploration of novel coating materials as well as functional designs for application related efficiency enhancements to increase sustainability.
The individual components are made of various material types such as composites, diverse steel grades, Ni- or Co-based superalloys, or intermetallics, all requiring specific interface designs for novel coating materials. Especially, additive manufactured components reveal a new field of coating development as their surface topography and microstructure ask for new advances.
This proposal covers the development of thin film materials for high-performance components, especially applied in aviation and transportation as well as energy production. Prominent examples are turbine related engine parts applied in geared turbo-fans or hydro electrical power generation, to mention just a few examples. Therefore, thin film materials execute diverse functionalities such as ultra-high temperature ablation- and oxidation-resistant coatings, thermomechanical barriers, or as erosion and fatigue resistant films. To enter new domains of operating ranges a knowledge-based recursive understanding between the target-synthesis-coating relationship as well as chemistry- structure-properties relation of thin film materials is required. The proposed research plan is based on a bottom-up understanding between failure related mechanisms, microstructure controlled properties, as well as synthesis related morphologies utilizing a combinatorial approach between various atomistic modeling techniques and experimental validation. The core functionalities of the projected coatings are implemented in the proposal consisting of the Module ‘Thin Film Materials Science’, separated into three main work packages (WP). WP I (Thermomechanical Wear) is focused on a systematic exploration of coatings obtaining ultimate phase stability, excellent damage tolerance, as well as fatigue strength or defined tribological behavior in extreme environments. Based on an ab initio molecular dynamics guided material selection, novel thin films – multinary transition metal ceramics as well as intermetallics – will be experimentally synthesized, characterized, and tested under application near conditions, up to field tests. In WP II (Transport Mechanisms) an in-depth understanding of transport mechanisms in thin film materials with respect to morphology and phase degradation is proposed. Diffusion driven deterioration processes such as corrosion or oxidation are major topics. Especially, a detailed description by advanced high-resolution (HR) characterization techniques such as 3D atom probe tomography, HR transmission electron microscopy, or X-ray nanobeam diffraction. WP III (Sustainable Synthesis Processes) will focus on the influence of phase constitution and alloying within target materials in relation to the ion flux formation during deposition – particularly, for arc evaporation but also sputter deposition. Such in-depth understanding on the target-synthesis-coating relationship can be applied to trigger e.g. phase formation processes within coatings due to specific target microstructures, increasing sputter yields by specific alloying concepts, or selectively deposit enriched macro-particles for application related purposes e.g. solid lubrication.
A knowledge based Surface Engineering, utilizing state of the art computational material science combined with advanced synthesis and characterization techniques, can decisively contribute to future requirements for high-performance Components applied in various industrial applications increasing sustainability.
