Customer Magazine 01|2019 BEYOND SURFACES From brush to pen: Professor Sampath on the (r)evolution of thermal spraying High up: Airbus launches the future of Big Data in aviation Let’s ﬂ ex our muscles: Optimal strength training with 3D printing
«There is almost no other area in which the demands for safety, weight, costs, and the temperatures to be mastered are com- parable to those of the construction of jet engines.» Dr. Wolfgang Konrad holding an engine component with thermal barrier coating from Oerlikon Metco.
A personal insight 3 COATINGS THAT FLY High tech for the aircraft and aerospace industry The aerospace industry is unique. It has been growing for decades. And it will continue to do so in the coming years because mobility is and will remain one of the most important achievements of our society – one that we are hardly prepared to go without. But it also fascinates me as an engineer: The construction of jet engines is simply the supreme discipline in mechanical engineering. There is almost no other area in which the demands for safety, weight, costs, and the temperatures to be mastered are comparable. And those demands continue to become ever greater: The objective is to reduce consump- tion – and thereby CO2 emissions – to avoid noise emissions and to increase the service life as well as safety. To accomplish this requires optimization of physical parameters in many different respects. And that is precisely what motivates Oerlikon: Engaging in development work at the very limits of what is possible in cooperation with the industry’s leading manufacturers. Together, we search out materials and methods that deliver ever greater performance and cost-effectiveness. An area in which our know-how is in particular demand involves what is known as “abradables”. On one side stands a “standard product”. On the other, we have high tech in its purest form. The coatings, developed from an intelligent mixture of metals and plastics, must be yielding, but also hard, which means they must wear as minimally as possible. Against the background of increasing pressures and ever higher temperatures in the compressors of aircraft engines, this is a balancing act between abrasive erosion and adhesion. To accomplish this tightrope walk successfully, coatings have long since ceased to be viewed as mere com- ponent protection. Instead, they are designed in right from the beginning of product development. Professor Sanjay Sampath of Stony Brook University in New York is among the experts with the most profound knowl- edge of thermal spraying. In the article starting on page 10, he provides us with insight into how design engineers incorporate the advantage provided by the potential of coatings from the start of the development process. He sees the clearest, most concrete and most measurable advantages in turbine engineering. And Mirjam Arndt, Head of R&D Product Development at Oerlikon Balzers, relates starting on page 6 how we are able to open up a wide array of previously unexplored ﬁ elds of application using new material systems and types of coatings. Donough Tierney, Vice President Canada & Europe at Airbus, tells us, starting on page 20, how the largest European aircraft manufacturer appraises the future of air travel. He reports that, against the backdrop of a world population that continues to grow relentlessly and the associ- ated increasing rise in density in our metropolises, the entire industry will change. One possible Airbus scenario involves “air taxis” which are envi- sioned as characterizing public trans- portation in the cities of the future. The prerequisite for this, however, is that new production methods and means of industrial mass production succeed in significantly reducing the manufacturing costs for flight vehicles of this nature. However, what applies there, applies every bit as much in other industry sectors. That is why we also are work- ing on this challenge on a daily basis. An example is our “Surface One”, the ﬁ rst machine for thermal spray coatings. Oerlikon Metco’s “intelligent factory of the future” can be converted very quickly to different applications and types of powders. We can learn about these starting on page 38. Increasingly shorter development and manufacturing cycles, enormous qual- ity and safety requirements and rising demands in the area of environmental protection: We are pleased to take on the challenge here. This issue of our magazine, BEYOND SURFACES, will show you a few examples of what we mean. Get ready to be surprised! Cordially yours, Dr. Wolfgang Konrad Head of Business Unit Metco Aero & Energy BEYOND SURFACES 01|2019
20 Technology & Innovation 6 Dimensions that were previously unthinkable Materials expert Mirjam Arndt on collaboration, cooperation, and partnership 10 The precision pioneer Prof. Dr. Sanjay Sampath on evolving the capabilities of coatings 16 Facts & Figures Technologies for Aerospace 20 Tracking the aerospace trend trajectory Expert interview with Airbus on the future of the aerospace industry 34 Spot on: The titan of metals What the metal titanium has to offer 36 Five minutes for a truly hot topic Interview with the winner of the OMYPA award 38 A compact future Experts are enthusiastic about Surface One Solutions 24 Eyeglasses = temples + rims (or even less) How designer Sven Götti redeﬁ nes rimless glasses 28 Artificial intelligence meets power A measuring instrument designed for strength training 6
News 15 Learning from the best Successful first Asia Press-Shop Meeting (APM) Oerlikon Balzers is “ Qualified Supplier” for Airbus BALINIT C coatings on copper alloys 23 More flexibility and better service quality New coating system in Switzerland A broader range of surface coatings Acquisition of TeroLab Surface GmbH Chrome look and top quality First INUBIA ePD coating system in China 32 At your side Even closer to our customers 10 Events 40 Trade show dates 41 Be part of it 3rd Munich Technology Conference on Additive Manufacturing 24 IMPRINT BEYOND SURFACES is the Customer Magazine of the Surface Solutions Segment of the Oerlikon Group. Date of publication: May 27, 2019 Publisher Oerlikon Surface Solutions AG Churerstrasse 120, CH-8808 Pfäffikon www.oerlikon.com/balzers www.oerlikon.com/metco www.oerlikon.com/am Responsible for content: Andreas Schwarzwälder, Head of Group Communications and Marketing Editor in Chief: Anika Köstinger, Senior Content Marketing Manager Layout: up! consulting Picture credits Ashton Worthington Photography (title page, p. 11, 12, 14); Jens Ellensohn (p. 2, 6, 8); Blaumann & Meyer – Sports Technology UG (p. 28, 29, 31); iStock.com (p. 15, 34, 37, 40); Airbus S.A.S. (p. 20, 22); Götti Switzerland (p. 24, 25, 27 ); Shutterstock (p. 34, 35); Alexander C. Wimmer, Creative Commons Attribution-Share Alike 3.0 Austria (p. 35); all others: Oerlikon Surface Solutions AG email@example.com BALINIT, BALITHERM, BALIQ, BALIIFOR, ePD, S3p and SUMEBore are brands or registered trademarks of Oerlikon Balzers or Oerlikon Metco and not separately marked. It cannot be concluded from a lack of marking that a term or image is not a registered trademark. BEYOND SURFACES 01|2019
6 DIMENSIONS THAT WERE PREVIOUSLY UNTHINKABLE by Agnes Zeiner
Technology & Innovation 7 Collaboration, cooperation, partnership. These words represent a recurring theme in our talk with Dr. Mirjam Arndt, Head of R&D Product Development at Oerlikon Balzers. And as we spoke, she covered a broad spectrum of topics, including her 15-member international team as well as colleagues in sales, customers and partners at academic institutes. “The key question we pose to ourselves daily is: How can we create new coatings, and thereby new products, that the market is demanding, either consciously or unconsciously?” explains the metallurgist and materials scientist. Her department is engaged in innovation manage- ment – and that is interpreted in the broadest sense possible: “Our colleagues in R&D Tech- nology develop the hardware components that are required for the coating process: for exam- ple, new arc evaporation sources. Our in-house engineering team and our R&D Technology department are together responsible for the development of systems,” Arndt says. “Here in R&D Product Development, we use these results to create new coatings, on the one hand, but also to enable the production of existing coatings with new system technologies.” technology there. Consequently, after projects in Germany, the USA and Israel, I came to Oerlikon Balzers in Liechtenstein exactly ten years ago. And now, I finally have the opportu- nity to influence not only coatings, but also the refinement and further development of entire technologies.” And right away, Arndt cites the INNOVENTA platform as an example. This system now enables highly complex coatings to be deposited in a decidedly productive manner. That means a greater quantity of different coating materials for complex coating architectures and nano layers – and what’s more, at speeds up to twice as fast as could be achieved previously. The result is that in addition to cutting applications, it is also possible to deal even better with the requirements for forming tools or certain precision components. System technology – a defining moment Her enthusiasm and passion for her job are clearly evident throughout our talk. After confer- ral of her doctorate and a post-doc year, she left her alma mater, RWTH Aachen University, for a position in industry at Germany’s METAPLAS, which today is also part of Oerlikon Balzers and thus the Oerlikon Group. “I worked on an aluminum-titanium-nitride coating there that has ultimately proven to be very successful – but that also required a refinement of the systems involved. That was something of a defining moment for me,” recalls Arndt. Her later work in the R&D Surface Technology department of a large industrial user made it possible for her to enhance her knowledge in the area of machining. “But as users, we had absolutely no way of influencing the system Real products instead of research work Has researcher Mirjam Arndt ever felt drawn to return to a university context? She laughs. “Well, sometimes, yes, but I am in constant contact with various institutes and research colleagues across the whole of Europe. At a university, research leads to publication. We, on the other hand, end up with a real product in our hands, and customers can actually use it. In fact, it’s not at all unusual for entirely new fields of application to be opened up, such as by our S3p technology [see box]. We also get feedback directly from the market – and that provides unbelievable motivation.” The team maintains close relationships with universities and research facilities across Europe to keep abreast of basic scientific research developments – for example, with RWTH BEYOND SURFACES 01|2019
88 Technology & Innovation «Every one of us must both comprehend our customers’ applica- tions and be prepared to complement each other and provide mutual support.» Aachen University, with EMPA in Zurich, and with the Vienna University of Technology, where an additional joint Christian Doppler Laboratory has been set up that commenced work on March 1, 2019. Its primary focus is surface tech- nology for highly loaded precision components, which is one of the strategic growth areas for Oerlikon Balzers. And, each one of these part- ners has Oerlikon Balzers systems installed, as Mirjam Arndt explains: “This ensures that we are conducting the basic scientific research on the ‘right’ systems. This research work produces ideas that can be incorporated in later product development projects. To do so, we prepare road maps for projects and products in coop- eration with our business units, and a detailed market and competitor analysis helps ensure that our development work is on target to meet the needs of industry.” Win-win situation for customers and developers There is close cooperation with customers, as well, because there are not laboratories geared to every specific application as there are with the in-house machining laboratory. Consequently, the team works together very closely with customers in the areas of forming tools and precision components, starting in the development phase. These partnerships achieve a win-win effect: “The customer gets a better coating, and we can improve our products thanks to the feedback from the customers and the results achieved in field tests.” Mirjam Arndt explains: “To develop a market- able coating, we need to understand precisely what the customers need, where the loading associated with the application arises – such as temperatures and forces – and what wear mechanisms are involved. We then translate this knowledge into the necessary coating properties. Fine tuning these is then the core expertise of my team.” And as for the team: When Mirjam Arndt talks about “her” 15 team members, who hold doctorates in materials science and physics and who come from twelve different nations, the pride she takes in her department is unmistak- able. She started with only two staff members. “My job was to expand the team, which often entailed helping scientists who came to us directly from a university and had no experience
in industry to understand our application-oriented coating product development work. Every one of us must both comprehend our customers’ applications and be prepared to complement each other and provide mutual support. We have no use for lone warriors. Moreover, Oerlikon offers an ideal environment that allows my staff to develop further within the company, either in their disciplines or in a management career, depending on their inclination. This ‘internal network’ then also ultimately benefits our department.” New materials require new coatings “ beyond nitrides” In addition to a well-filled development pipeline, the R&D Product Development also deals with future trends. Arndt sees the greatest challenge in the area of new base materials, which will need entirely new coating solutions. These can be new substrate materials, for one thing, that require innovative protective coatings – for example, in the area of precision components – or new materials requiring processing with cutting tools or forming tools. For instance: a new class of material systems with greater thermal and/or chemical stability characterized by higher hardness. This will open up entirely new fields of application. At the same time, however, these materials are also highly brittle and therefore demand new coating mate- rials beyond conventional nitrides. “In the aero- space sector, these can be new base materials for turbines, for example, that must be able to withstand significantly higher temperatures than previously,” says Mirjam Arndt with a view toward the future. “Consequently, we will need to offer new protective coatings resistant to extreme tem- peratures and oxidation. In the energy production sector, we are dealing with lower temperatures, by contrast, but corrosion and erosion resistance are extremely important here, which we will need to achieve with coating development work outside of today’s PVD spectrum.” Mirjam Arndt and her team won’t be getting bored any time soon: “We want to be able to offer our customers products for these new applications,” she says. “For us, that means we must begin to change the way we think – in dimensions that have previously not been imag- ined because they simply were not possible. This is the challenge that we are already working on together with our partners.” 9 S3p – A Smooth Revolution S3p technology combines the advantages of arc evapo- ration and sputtering technologies. The unique process window and the separate scalability of the pulse duration, pulse shape and current density open up new possibilities for customer-specific coating design that is marketed in the BALIQ product family. Application examples for this technology include micro tools or threading tools, which require precise and smooth high-performance coatings. www.oerlikon.com/balzers/s3p www.oerlikon.com/balzers/s3p-coatings INNOVENTA More loading capacity, lower maintenance requirements and many new functions. The INNOVENTA platform comprises PVD systems in three sizes for more flexibility, productivity and connectivity. www.oerlikon.com/balzers/innoventa BEYOND SURFACES 01|2019
10 THE PRECISION PIONEER Prof. Dr. Sanjay Sampath is Distinguished Professor and Director of the Center for Thermal Spray Research at Stony Brook University in New York. He studied metallurgy at an institute in his native India, but a scholarship to complete his Ph.D. in the U.S. changed his career course. by Randy B. Hecht Metallurgy typically involves making big things like castings and forgings. “At Stony Brook, they were taking metals and even ceramic and basi- cally making raindrops – thermal spray – and impacting on the sur- face,” Sampath says. “When you do that, you operate at extreme condi- tions of metallurgy or materials. That captivated my attention.” He uses “pretty much all” of Oerlikon’s equipment, including plasma spray and supersonic combustion equip- ment, and more than a dozen of his former students have worked at Oerlikon Metco’s facility in Westbury, New York. Teaching remains import- ant to him because “I start to realize how you should manipulate your own thinking,” he says. “Everyone should teach, because then they’ll know their subject better.” How is thermal spray technology evolving? Thermal spray was widely used by skilled practitioners, not necessarily scientists and engineers. That’s how the technology started. We made it into a rigorous scientific and tech- nological capability. And that has paid dividends. We have effectively transformed the technology from an art form to a robust, scientifically strong engineering technology. How does that translate to benefits to people, society and the planet? When thermal spray started, only a few people could do it well. In manufacturing, you want the tech- nology to be more scalable, reliable and reproducible. You want a rigorous manufacturing technology. And you can only achieve that if you under- «I tend to go out of my comfort zone, because you can convince yourself you know everything until you see someone who tells you something completely different.» stand the science and the technology behind the process. The consequence of that is, we have a much larger market base, and the technology is used in more industries. Coatings were generally used as an afterthought to maybe improve functionality. Now design engineers are taking advantage of coatings as an actual capability. That has allowed the industry to ﬂ ourish. Aircraft engines and power generation are the areas where the impact is most signiﬁ cant, with a double digit increase in efﬁ - ciency, a signiﬁ cant reduction in CO2 – those are where you actually see the tangible, measured beneﬁ ts. One area of your research is ther- mal spray processing of materials, synthesis, and application of multilayered surfaces. Can you help us understand that? Let’s focus on the word multilayer, which I think is the future. When the technology was not very strong or the understanding was not very good, people just sprayed the same coating layer. But with our knowledge and the capabilities of the technology, we are depositing coatings not as monolithic uniform material, but as something more like designer structures. No one material can satisfy all your needs. By layering them in a clever, strategic way,
Technology & Innovation 11 Prof. Dr. Sanjay Sampath Distinguished Professor and Director of the Center for Thermal Spray Research, Stony Brook University BEYOND SURFACES 01|2019
12 you can do many things at the same time, which is what we call multifunc- tionality. You basically stack materials (or material attributes) in layers, very similar to how they build semiconduc- tor chips. We’re trying to do something like that on a large scale. Another area of your research is the evolution of microstructures associated with suboptimal condi- tions in terms of equilibrium. What should we know about that? An important aspect of thermal spray that is not well appreciated is that we basically create these modern raindrops of very high-temperature materials. These things hit the surface and cool extremely fast – like a million degrees per second. When meteorites impact with the Earth, you have craters, right? We do something like that at a very small scale. Each one of these droplets is the diameter of your hair. We’re taking these things and projecting them at extremely high temperatures and velocities. They cool very fast and impact at high energies, and so we use the term that these are materials synthesized from extreme conditions. What we’re trying to do is essentially bring in new ways to integrate these non-equilibrium processes. The global thermal spray community had to basically rebuild the whole research enterprise to think in a very different way that is not following tradition or established engineering thinking. You also have “pioneered the development of mesoscale direct writing technologies based on thermal spray for applications in prototyping and manufacturing of wide-ranging thick film sensor structures, thick film electronics, and mesoscale multifunctional systems.” Is there a way to understand that? I’ll simplify that. Thermal spray is a paintbrush. It creates broad, sweeping paint swaths. For a U.S. government project, I was asked to make a thermal spray pen rather than a paintbrush. That’s what mesoscale direct writing means. We took a thermal spray paintbrush and made it into a thermal spray pen. «We have effectively transformed the techno- logy from an art form to a robust, scientifically strong engineering technology.» The history of thermal spray technology: collection of historical devices at Stony Brook University. BEYOND SURFACES 01|2019
That’s not easy to do. It took more than $10 million and a lot of labor to get there, because you can’t simply miniaturize thermal spray. It takes a tremendous amount of not only understanding, but also hardware, to implement that. Because we can now write in addition to paint, now I can do interesting things with it. For example, I can write a circuit on top of a coating that will allow me to sense what the component operating temperature is or collect electro magnetic signals by printing antennas on structures. This is a normal way to combine layering and printing and allows us to do direct writing. Imagine if I can pattern materials precisely the way I want in 3D. Not only do I need a pencil or a pen to be able to write, but I also need the robotics and machine tools that allow me to actually print a circuit on a 3D part. We can write an antenna on top of an existing part – for example, on a helmet or even an aircraft structure. In fact, that’s what we did. There are two important innova- tions. One is that we created a high-definition thermal spray printing process – which was revolutionary, and the technology is now being used commercially. And second, now we can take thermal spray and write as well as paint. We can build electronic Technology & Innovation 13 devices, which are basically lines and layers. To do that, you need tremen- dous understanding of how you not only miniaturize these things but also get the correct material attributes. That required knowledge of thermal spray at a level that was not easily available. And if you’re making things so small, can I still get the materials to work right? That was the second big challenge. These two had to come together for the technology to succeed. That was possible only because of all the foundational work we had done in thermal spray.
14 Technology & Innovation So you are pioneering new levels of precision. How much further can that precision be taken? This was considered a disruptive technology, so it came in sideways. The problem is, you then have a capability that’s looking for an appli- cation. That’s always a difficult thing to address. We have done a lot of innovation, maybe even reached the limit of what we can do with today’s technology. The real future effort is taking advantage of this breakthrough to many applications. And that is going much more slowly than we thought. My guess is that in the next 10 years, people will start to see more and more concepts of these intelligent machines. Which areas of industrial develop- ment of thermal spray technol- ogies do you monitor, and how do they affect the direction of your research? I tend to go outside the mainstream to seek ideas. If you talk among yourselves, you’re not going to make progress. So I continue to collaborate with my peers, but I go out of my comfort zone. You can convince yourself you know everything until you see someone who tells you something completely different. Constantly challenging one’s own view is in my mind very important. Where do you see the best oppor- tunities for academia and industry to work together toward further development of this technology and its practical applications? I created the Consortium for Thermal Spray Technology, which involves 30 companies. The idea is linking research to practice. Oerlikon is a founding member and a big supporter of it. And Oerlikon is a supplier of thermal spray equipment and materi- als, but its customers are companies like General Electric, Rolls-Royce, Siemens and Caterpillar. Our Consortium has all these companies as members. It’s a unique business model because we have competitors and customers in the same room. And that has been a successful and rewarding journey. We’ve met every six months for 15 years, and gener- ations of students have experienced this concept of consortium. We’ve been able to convince the companies that our fundamental research can provide value to their products and manufacturing pro- cesses – essentially to their bottom line. You have to provide value to companies, give them something they can actually use, and at the same time, make them realize that your fun- damental research has value for them. For that to happen, you must under- stand what their needs are so there’s a very good partnership. Ultimately, we have to make the pie larger so we all can have a bigger piece of it. BEYOND SURFACES 01|2019
Technology & Innovation 15 Successful ﬁ rst Asia Press-Shop Meeting (APM) LEARNING FROM THE BEST Exchanging information, discussing Their focus was on current issues: the stamping industry, this means together and learning from one What opportunities and challenges higher productivity and more rapid another for a better future: this for the punching industry do vehicles model changes. In the automotive was the theme of Oerlikon Balzers’ with alternative drives present? industry, this allows the manufacture invitation to the ﬁ rst Asia Press- What challenges are found in a of vehicles with lower weight and Shop Meeting (APM), which was full-aluminum vehicle body? What energy consumption. Surface treat- held October 30–31, 2018 in its does the term automotive punching ments and new coating solutions for customer center in Suzhou (China). industry 4.0 mean? Representatives stamping and machine tools were Through numerous lectures as well from Beijing Benz, BMW Brilliance, also important topics in discussions as in a roundtable forum, more Dongfeng Nissan, Ford Motor, about how to achieve further than 120 leading OEMs and Tier 1 Honda Motor, SAIC and many others increases in stamping productivity suppliers shared their knowledge provided insights into advanced while lowering production costs. and experience in the ﬁ eld of concepts for materials, tools and punching and forming technology. manufacturing processes. For BALINIT C coatings on copper alloys OERLIKON BALZERS IS “QUALIFIED SUPPLIER” FOR AIRBUS Airbus has given the status of “Qualified Supplier” to tive to hard chrome plating. The sites in France and the Oerlikon Balzers customer centers in the United the United Kingdom have already been certified by Kingdom and France for their BALINIT C coatings on Airbus for the coating of steel, titanium and Inconel. copper alloys. This coating reduces surface fatigue In addition to the sites in Canada and Luxembourg, when applied to aircraft components so that they they are also NADCAP- certified (National Aerospace are more resistant to the wear and high loading they and Defense Contractors Accreditation Program) and experience. At the same time, they are light and less offer first-class coating solutions and services for the susceptible to friction. Moreover, BALINIT C is known aerospace industry. as a non-hazardous and REACH-compliant alterna- BEYOND SURFACES 01|2019
Hot ﬁ gures for a booming market Aerospace is one of the fastest growing markets worldwide. Since 2016, passenger volume has almost doubled – a pace far faster than the International Air Transport Association’s (IATA) estimate. In 2018, a record 4.1 billion passengers ﬂ ew by plane. That’s the equivalent of over half the earth’s population. And still, demand accelerates. In response, aerospace companies are developing next-generation airplanes. At the same time, they need to increase efﬁ ciency and sustainability. INTAKE 25 – 450 °C COMPRESSION 450 – 850 °C EXHAUST 2,000 – 1,100 °C COMBUSTION 1,100 – 2,000 °C
Aerospace industry challenges of today The aerospace industry is marked by ever shorter development and manu facturing cycles, enor- mous quality and safety demands and increas- ing environmental protection requirements. Aircraft producers and parts suppliers are ex- pected to eliminate expensive tooling, short- en production lead times, reduce weight, eliminate waste, customize parts and inte- grate designs to reduce the number of parts that require assembly. Oerlikon aerospace solutions help them to produce and operate efﬁ - ciently, environmentally friendly, and safely. INCREASED COMPONENT LIFETIME Oerlikon Balzers’ aerospace solutions offer environmentally friendly coating technologies that reduce operating costs by increasing fuel efﬁ ciency, extending service intervals and protecting valuable components from all types of wear. BENEFITS + wear resistance + low frictional coefﬁ cient + corrosion resistance + erosion resistance MAXIMUM PROTECTION FOR HOT PARTS Oerlikon Metco’s next-generation solutions are designed to protect key aerospace components from wear, corrosion, oxidation and thermal attack. Our materials, functional coat- ings and turbine components are essential to jet engine operational efﬁ ciency, performance and safety. BENEFITS + thermal protection + wear and corrosion protection + clearance, sealing and cooling control + increased engine efﬁ ciency and safety CUSTOMIZED DESIGN SOLUTION Additive manufacturing (AM) is a technology that has the potential to disrupt aviation supply chains and change the future of aircraft design, manufacture and repair. AM enables lower part weight, new design possibilities and the integration of multiple parts into one. Equally important, it can be used to produce more complex parts than are possible through traditional manufacturing techniques. BENEFITS + lower weight + improved stability + parts reduction + impact protection
Compressor Blades Turbine Blades Antenna Bracket USE CASE Coatings to protect blades The high hardness and fatigue resistance of BALINIT TURBINE PRO protects against abrasive wear, solid particle erosion and liquid droplet erosion. This makes this PVD coating ideal for highly stressed precision components such as compressor blades, even under high thermal conditions. 40× MORE EROSION RESISTANT THAN STEEL 5× MORE EROSION RESISTANT THAN OTHER PVD COATING SOLUTIONS USE CASE Coatings to boost engine performance Thermal Barrier Coatings (TBCs), including environmental barrier coatings, are used in the hot sections of engines. They provide outstanding thermal protection and enable higher combustion temperatures. This results in better fuel and engine efﬁ ciency, and – by burning more carbon dioxide – reduces the impact on the environment. + 2,000 °C OPERATING TEMPERATURE 5% EFFICIENCY BOOST 1 – 3% FUEL EFFICIENCY GAINS USE CASE 3D printed parts to reduce weight Oerlikon and RUAG Space worked together on the qualiﬁ cation of a sentinel satellite antenna bracket for a payload fairing. A new optimized design made possible through additive manufacturing (3D printing) reduces costs, decreases weight and doubles the stiffness of the bracket. 25% LESS COST 50% LESS WEIGHT 2× STIFFER
things you probably didn’t know about aircraft jet engines USE IN POWERPLANTS GE is taking the world’s largest jet engine (GE90-115B) and turning it into a power plant. The new electricity generator (LM9000) will be able to generate a whopping 65 megawatts, enough to supply 6,500 homes. THE SIZE OF AN ELEPHANT The current biggest and most powerful passenger plane jet engine weights around 8.28 tons, measures 3.43 m in diameter and is 7.29 m long. Even more than a grown up African elephant. HOTTER THAN LAVA With temperatures of over 2,000 °C inside the combustion chamber, a jet engine has to withstand temperatures hotter than lava. FORMULA 1 POWER A Trent 1000 jet engine from Rolls
20 TRACKING THE AEROSPACE TREND TRAJECTORY The global volume of airline passengers has increased dramatically in recent years: More than one third more people boarded an aircraft in 2018 than did just five years ago. Demands for operational efficiency and sustainability are equally in focus, both for aircraft manufactur- ers and airlines. Donough Tierney, Vice President Canada & Europe at Airbus Industries relates what factors will influence the sector in the years to come. BEYOND SURFACES 01|2019
Technology & Innovation 21 What does the aerospace industry mean for you personally? What fascinates you the most? Aerospace is one of the most interesting industries I have worked in. The technology and various business models across the industry have a major effect and impact on three levels. At Level 1, aircraft development creates valu- able and sustainable high-tech jobs. At Level 2, the spin-off from aircraft manufacturing has a major direct and indirect impact on the supply chain that can stretch over many countries. At Level 3, the aircraft produced and sold to air- lines in recent years have led to a huge increase in air travel that has changed our ability to move across countries and continents at a reasonable price and at the same time has sparked the growth of aerospace hubs. What major trends currently drive the aerospace industry? There is a range of trends, passenger experi- ence for example, through various innovations, including increased space, comfort and environment. On the operational side, we’re discovering how to maximize fleet performance and reduce operational expenditure. In these areas, data analytics can play a major role. Airlines are looking for ideas that can have a positive effect on fuel consumption, which is a major airline cost, and aircraft maintenance. When aircraft are not flying, they are not making money for airlines – hence the need to make sure that maintenance is performed off-peak or through scheduled checks. Environmental impact is now being heavily considered, and new solutions including hybrid and electric aircraft are developing and will be introduced in the future. Battery technology will have a major impact on the pace of this development. Given the emergence of major urban transport hubs, airport development is looking to cater to increased traffic while managing customer expectations. Technology is playing a major role in design and personalization, leading to higher retail expenditure, and to maximizing operational improvements on both land and airside. Can you describe one or two examples of digital transformation’s impact on your business and how Airbus manages them? Airbus has launched a new aviation data plat- form in collaboration with Palantir Technologies – pioneers in big-data integration and advanced analytics. Skywise aims to become the single platform of reference used by all major aviation players to improve their opera- tional performance and business results and to support their own digital transformation. Skywise is already improving industrial opera- tions performance throughout Airbus’ industrial footprint, and it is now possible to deliver enhanced aircraft and equipment designs, better service and support offerings based on deeper in-service data insights. Servitization is an area where Airbus is growing rapidly, and digital transformation allows for better customer offerings. A good example of this is the Flight Hour Service (FHS) business, which allows for increased operational reliability. Airbus FHS provides fully integrated component services, including spare pool access, onsite stock replenishment at the main base and components repair. Through FHS, Airbus offers airlines its extensive and proven expertise in fully integrated maintenance services, and the advantage of its OEM expertise as well as one single interface to manage their whole fleets and associated component support operations.
Donough Tierney, Vice President Canada & Europe at Airbus In the 15 years Donough Tierney has worked with Airbus, his primary area of focus has been International Development. The scope of this work encompasses devising and implementing country and region strategies and working on International Cooperation for large and strategic campaigns, which may include responsibility for roadmaps, industrial projects and aligning resources with objectives. In addition, his hands-on role in regional approaches and business development draws on his expertise in political affairs, strategy, industrial development and sales and gives him impact in areas as diverse as the United Nations, Multinational Organizations and the Arctic. 22 Technology & Innovation Airbus is working on solutions for future air mobility in cities. What do these solutions look like, and when will they come into operation? Growing urbanization and the associated need for mobility are key megatrends in our century: by 2030, 5 billion people, 60 percent of the population, will live in cities. This leads to ever-growing congestion problems and associated costs, both of which reduce the living conditions of the citizens. Within the future smart city, there is a strong opportunity to overcome the constraints of ground transport by using Airbus territory: the third dimension. Within this framework, Urban Aircrafts are potential solutions for on-demand and shared air mobility. CityAirbus has been tailored to the needs of urban environments. It features a fully electric “multicopter” design combined with a radically simplified architecture. Autonomy features will reduce pilot workload and increase safety. In addition, new production technologies and industrialization for mass production will reduce costs significantly. Key enabling drivers are safety, cost and noise to ensure techno- economic feasibility and public acceptance. What role do partnerships play in designing our future air travel solutions? The collaboration economy will reach new heights in the coming years, as many solutions will be introduced to improve the overall travel experience. As air travel continues to grow, so too will the partnerships with existing and new technological partners. BEYOND SURFACES 01|2019
News 23 More ﬂ exibility and better service quality NEW COATING SYSTEM IN SWITZERLAND Acquisition of TeroLab Surface GmbH A BROADER RANGE OF SURFACE COATINGS The INGENIA family’s new PVD coating system was With the acquisition of TeroLab Surface GmbH in Langenfeld formally inaugurated at the Oerlikon Balzers coating ( Germany), Oerlikon Metco has expanded its range of coating center in Brügg (Switzerland) in November 2018. The solutions with additional market applications, especially in the new investment signiﬁ cantly increases production capacity agri culture, printing, steel, automotive and mechanical engineering and, most notably, the ﬂ exibility and quality of service. sectors. “We are now able to offer our customers a more compre- “The INGENIA’s smaller coating chamber allows us to hensive range of surface coatings to improve the reliability and dura- reach a full batch load more quickly, even for coatings that bility of components and parts,” says Dr. Wolfgang Konrad, Head we previously were able to offer only at longer intervals. of Business Unit Metco Aero & Energy. This acquisition strengthens As a result, we can now guarantee shorter delivery Oerlikon’s market position for coating services and brings the times to meet speciﬁ c customer requirements,” explains business yet another step closer to its customers. In the future, Andrea Hürlimann, manager of the customer centers in TeroLab Surface GmbH will be active as Oerlikon Metco Coating Switzerland and Liechtenstein. Services GmbH in the Oerlikon Metco Aero & Energy business unit. Chrome look and top quality FIRST INUBIA ePD COATING SYSTEM IN CHINA Automobile company Shanghai “embedded PVD for design parts”, ePD wide array of decorative exterior parts. Dafangwuyu (DFWY) signed a purchase is an environmentally friendly coating The INUBIA I6 makes it possible for agreement for the first INUBIA I6, a process that uses no harmful chemicals DFWY to serve its customers in the fully integrated and automated coating whatsoever. The system enables mass automotive industry with chrome-look system, in China. The system uses production in accordance with the components of top-flight quality. “The the ePD technology developed by automotive industry’s requirements. ePD technology is a promising, environ- Oerlikon Balzers to produce metalized DFWY, a Tier 1 or Tier 2 supplier for mentally friendly coating solution that plastics with a chrome look and rep- national and international OEMs, was meets the high protection requirements resents a clean alternative to conven- recently awarded a contract for the of our automotive customers,” says tional galvanizing. The abbreviation for mass production of ePD coatings for a Chairman Anthony Huang. BEYOND SURFACES 01|2019
24 Solutions Sven Götti, CEO and founder, Götti Switzerland
25 EYEGLASSES = TEMPLES + RIMS (OR EVEN LESS) Eyeglasses consist of two temples, a bridge, the rims and a few more small parts. You might think that provides limited options. Far from it: This drives designer Sven Götti to new heights of creativity. And with his “Götti Perspective” collection, he has gone one step further by redefining rimless eyewear. The new concept also employs BALINIT C from Oerlikon Balzers. by Agnes Zeiner BEYOND SURFACES 01|2019
26 «Using AM makes us enormously flexible, so we can not only offer a widely diversified model range in our ‹Dimension› collection, but can also produce ‹on demand›.» Even after 25 years as a designer, optician Sven Götti is still fascinated by eyewear: “Yes, it’s true – we’re still dealing with the same prod- uct. But it’s even more exciting now, and the combination of fashion accessory and precision mechanics embodied by glasses is totally unique and challenges me every day.” Perhaps that is the essence of the fascination Götti eyeglasses engender. They are not merely about an attractive design, top fashion or a certain “look”. Sven Götti’s team consists of 30-odd opticians, industrial designers and design engineers. And at headquarters in the town of Wädenswil on Lake Zurich, there is a separate development department. Small and clever Why does an eyewear brand need design engineers and its own development department? “We started this about three years ago when we wanted to design a pair of glasses that didn’t require any soldering, screws or glue,” explains Götti. The result is the “Perspective” collection – minimalist, rimless, aesthetic. Not a single screw is anywhere to be found. On a tour through the small production facility, the designer’s passion – and that of his staff – is palpable: “We make the individual parts out of Sandvik stainless steel, which makes the glasses ultralight and flexible. The decisive connecting piece for the eyeglass lenses is manufactured with 3D printing. All of the parts are fabricated here in Wädenswil as well as in three foundations in Switzerland where people with disabilities carry out repetitive production tasks for us. The tools that local opticians require to connect the components with the lenses are also the result of our own development work.” It all comes down to the coating The rimless “Perspective” models are available in eight colors. For black, Götti brought a partner on board who is also known for Swiss precision, because only the BALINIT C coating from Oerlikon Balzers, normally used for high- tech tooling, was able to satisfy the designer’s demanding requirements. “I was looking for a partner that stands for ‘made in Switzerland’, as we do as well,” he explains. But it wasn’t just the color that convinced him: The coating also makes the eyeglass components scratch- and abrasion-resistant as well as impervious to environmental influences. Printed glasses And what about 3D printing – did we hear that correctly? Yes, in Götti’s production department there is also a printer that uses white polyamide powder and a finely tuned color mixture that prints not only tiny connecting parts, but also entire glasses. Götti has employed his own CAD designers for this purpose. “This makes us enormously flexible, so we can not only offer a widely diversified model range in our ‘Dimension’ collection, but can also produce ‘on demand’. Peak periods are buffered by an external partner.” And what’s coming next? The designer smiles: “My vision is the question: How far can we take this? Innovation is the lifeblood with which we seek new solutions – and create an endless array of shapes from the same parts.” Eyeglasses consist of two temples, a bridge, the rims and a few more small parts. After a visit to the Götti Switzerland facility with Sven Götti, however, it is clear that there is more. Much more. Or, perhaps, less.
Solutions 27 BALINIT C Color design and functionality BALINIT C is a WC/C based coating, meaning Highly decorative and wear resistant at the same it is a mixture of metal (WC stands for tungsten time – the coatings in the Oerlikon Balzers “Design carbide in German) and diamond-like carbon (C). Line” deliver high-quality, colorful surface coatings The coating reduces surface fatigue and tribo- that provide even more creative flexibility in product oxidation. BALINIT C is typically employed for design. The coatings are extremely thin, which gear wheels and ball bearings subject to high enables the existing structures to be replicated with surface pressure and heavily loaded precision precision. Matte or gloss effects are applied prior to components in internal combustion engines. coating by blasting, brushing or polishing. Applica- Further applications include punching and forming tion areas include the plumbing sector, automotive tools, but also the pharmaceutical and food- interiors, parts for clocks and watches, writing processing industries. implements, eyewear or electronics components. www.oerlikon.com/balzers/balinit-c www.oerlikon.com/balzers/designline BEYOND SURFACES 01|2019
28 Solutions ARTIFICIAL INTELLIGENCE MEETS POWER A start-up in Magdeburg, Germany, has developed a measuring instrument that helps athletes attain optimal results from strength training. The polymer housing is from Oerlikon AM in Barleben. by Gerhard Waldherr BEYOND SURFACES 01|2019
It has the same size and appearance as a rubber eraser: A black housing with a lightly roughened surface in which a small orange V is embossed. The Vmaxpro has a sleek exterior. What actually makes this small device exceptional, however, are its inner workings, which could soon take the arena of popular sports by storm. The fact that it also has a story to tell about additive manufactur- ing makes it just that much more intriguing. Location: Magdeburg, Lorenzweg 43. The office of Blaumann & Meyer – Sports Technology UG can be found on the second floor of a yellow Art Nouveau villa. Marcel Blaumann, an athletic young man who talks about his product with enthusiasm, is waiting. From the electronics to the design and even the associated app, everything is the result of his own development work, he says. And, naturally, he wants to provide his visitor with a demonstration of how it works. Blaumann fetches a barbell and places it on the floor. The Vmaxpro sticks to the bar magnetically. Blaumann starts the app on his smartphone. He selects the category of “mus- cle building” and “deadlift” as the exercise. The app, your friend and trainer What happens next is fascinating. Artificial intelligence meets power. The app says: 55 kg, three repetitions to warm up. Blaumann lifts the barbell three times. The system reports the speed of motion in seconds per meter. The smartphone instantly displays the maximum weight in dependence on your personal day’s form (196 kg) as well as the optimal weight (142 kg) for the training session. The next instructions: five to six repetitions at 142 kg. In addition, a graphic shows the primary stimulus that will be applied to the muscles. “The system,” explains Blaumann, “inter- prets all the available data: the lifting speed, previous training performance, general sports science findings as well as my personal form today. It uses this to calculate the optimal strength training session for my individual training objective.” Solutions 29 Marcel Blaumann CEO, Blaumann & Meyer – Sports Technology UG He studied mechatronics in Mannheim and subsequently worked for ABB, an energy and technology firm with headquarters in Zurich. In his free time, he engages in mixed martial arts, which also entails strength training. “The danger in strength training,” says Blaumann, “is overdoing it, which leads to injury. Doing an exercise with too much weight increases the risk of injury. Using too little weight doesn’t bring results. The question of how to optimize strength training has always been on my mind.” Algorithms to make you strong That question was also a factor in his second course of studies, Sports and Technology, in Magdeburg. Blaumann knows: “Speed is the key. In weight lifting, for example, an athlete knows that if he can achieve a certain speed, he’ll manage the weight.” There are devices available that measure speed during strength training, but they are extremely expensive and are therefore used only in professional sports. They also record and analyze the motion of the barbell. “Eighty percent of what an athlete does right or wrong can be recognized based on the motion of the barbell.” Blaumann is convinced that everyone who engages in strength training needs that BEYOND SURFACES 01|2019
30 information. “There are huge numbers of ambitious recreational athletes who go to the gym and lift weights but are ultimately frustrated when they don’t reach their goals.” Because they are training wrong. Because they aren’t being instructed or monitored and hardly anyone can afford a personal trainer. And that is where the idea for the Vmaxpro was conceived. During an internship at the Olympic Training Center in Magdeburg, he met the sports medicine scientist Dr. Guido Meyer, who was immediately fascinated. The idea of starting a company was proposed. This is the point at which Oerlikon came into play. Blaumann had put together the electronics and developed the software; there was even a design for the housing already. But he had no idea how to get it made. An injection mold costs considerably more than 10,000 Euros. Too expensive. Initial trials with a 3D printer found via the Internet proved unsatisfactory. The electronics package was still too large. The shape didn’t fit. The usual problems a start-up faces. Blaumann needed professional support, so he consulted with professors and fellow students. Ultimately, one said: “Why don’t you go to citim?” Located in Barleben near Magdeburg, citim was established in 1996 as a spin-off of the University of Magdeburg and is one of Europe’s additive manufacturing protagonists. The first laser sintering system (plastics) was installed in 2004 and the first laser beam melting system (metal) in 2009. Currently, the company has more than 20 printers for metal and ten for plastics. Since 2017, citim has been part of the Oerlikon Group. «Eighty percent of what an athlete does right or wrong can be recognized based on the motion of the barbell.» BEYOND SURFACES 01|2019 Win-win for Oerlikon and customer “We are always happy to get inquiries like the one from Blaumann & Meyer,” says Nils Raschke, Project Manager AM Polymers at Oerlikon. Especially because the challenge with the Vmaxpro did not involve metal powder, but rather polymers and the require- ment of achieving a surface quality that was suitable for series production. “With projects like this,” says Raschke, “we can improve our ‘out of the box’ production skills. All our customers benefit from this learning effect.” What’s more, Oerlikon AM is naturally inter- ested in promoting the theme of additive manufacturing, especially in Magdeburg as a center of technology. A little later, the scene has changed to the Oerlikon AM production shop. There is humming and whistling and hissing, as 3D printers, CNC machines and printed parts are everywhere. Raschke opens the door to a separate area with glass walls. There stands the M2 from the California company Carbon, with which the Vmaxpro is printed. It is a futuristic looking white cylinder. At the top is a semi-circular pane with a golden shimmer. The Continuous Liquid Interface Production (CLIP) process used for printing here was developed by Carbon. With it, objects are fabricated from a liquid synthetic resin using UV light. A glance through the pane reveals a product taking shape not layer by layer, but slowly as a single piece. It looks as if an object were being pulled out of a thick, black soup. The part is subsequently cleaned in what is known as a washer. Afterward, it is hardened in an oven at from 120 to 210 degrees Celsius for eight to twelve hours, depending on the plas- tic used. In contrast to laser sintering, the end product has a fine surface texture that looks as if it were the result of injection molding. And the best part: A housing for the Vmaxpro, which consists of three parts, costs Blaumann & Meyer significantly less for a series of 1,000 pieces than it would using injection molding. It’s also possible to incorporate modifications later on quickly and cost effectively.
Solutions 31 The system interprets all the available data and calculates the optimal strength training session for the individual training objective. Headlines worldwide Carbon and its CLIP technology recently attracted international attention as Adidas presented its first polymer soles fabricated by means of 3D printing. They are the foundation for a custom sports shoe adapted perfectly to the foot of any athlete. In addition, Ridell, a manufacturer of helmets for football play- ers, is now working with this 3D process for padding. Experts are already talking about a new trend in the sporting goods industry that will permit more creativity and change not only what, but also how, products are manu- factured in the future. in Germany for all Olympic disciplines and all team sports. “The feedback is thoroughly positive.” Blaumann’s real objective, though, goes beyond professionals and Olympic athletes. He wants to conquer the whole range of popular sports. He recently sold 250 of his measuring instruments by means of crowd funding. That has secured the continuation of the business for the time being. But to market his product on a large scale, he needs an investor. Blaumann says: “Then we could really get moving.” The 3D printers at Oerlikon AM in Barleben are ready to go in any case. One could say that also holds true for Blau- mann and his Vmaxpro, which is already in use at almost all Olympic Training Centers www.vmaxpro.de www.oerlikon.com/am BEYOND SURFACES 01|2019
32 News 1 Plymouth 1 Plymouth AT YOUR SIDE Even closer to our customers 2 Manesar 2 Manesar 1 AT THE FOREFRONT Super alloys and titanium materials from Plymouth Oerlikon’s state-of-the-art powder metals manufactur- (read more from page 34 about this chemical element, ing facility is located in Plymouth (Michigan, USA). In which is used to produce strong and lightweight alloys operation since summer of last year, the factory produces for aerospace, biomedical and other industries). The super alloy and titanium materials for additive manu- installed processes deliver highly spherical and fully facturing and coating processes. The powdered metals dense metal powders with significantly reduced surface are used mainly for aerospace, energy, medical and contamination, which is important for titanium implants in automotive applications. the biomedical industry. The Plymouth facility features latest gas atomization Plymouth is another step in Oerlikon’s efforts to save valu- and spheroidization equipment and has full capacity able resources: All installations have been built with a focus to produce, for example, high-purity titanium powders on minimizing loss of process energy and raw materials. Oerlikon’s Plymouth operation: at the forefront in the production of super alloy and titanium materials.
News 33 2 INDIA’S LARGEST CUSTOMER CENTER INAUGURATED Oerlikon Balzers India inaugurated its larg- only enlarges the production floor space, shortened considerably. “We want to offer est production center in Manesar (India) but also provides a widely diversified our customers the best possible service. in October 2018. The guests of honor in range of services offered throughout India. That’s because it’s our technologies and attendance included H.S.H. Hereditary Customers can now have even large-scale services that make the difference in the Prince Alois of Liechtenstein and Dr. Doris forming tools coated. There are additional hotly contested and booming Indian Frick, Liechtenstein’s ambassador to capacities available for cutting tools as market,” comments Marc Desrayaud, Switzerland. The new customer center not well, and all delivery times have been Head of Oerlikon Balzers. “GREEN THINKING” AT OERLIKON BALZERS Climate neutral and easy on resources Conserving resources as well as pro- site. The electricity required comes from current trends in climate and environmen- tecting the environment and health: hydroelectric and solar power, while heat tal protection continuously and evaluate Oerlikon Balzers pursues this goal not is supplied from a wood-fired heating which new technologies could contribute only for its customers, but also in its own plant. Even the waste management system to climate-neutral site development. right. Thanks to a climate-neutral energy has been optimized: Use of a vacuum Sustainable management is important to supply and waste management system, evaporator reduces the annual amount us,” explains Marc Desrayaud, Head of the company is not required to pay a CO2 levy at the Balzers (Liechtenstein) of special waste by 26 percent, or about Oerlikon Balzers. 23 metric tons annually. “We follow the BEYOND SURFACES 01|2019
34 TITANIUM AS ONE OF THE METALS Atomic number: 22 Chemical symbol: Ti Relative atomic mass: 47.867 Series: transition metals In our new Plymouth facility, we work intensively with Titanium. Therefore, we had a closer look at the element. Special properties Named after the Titans, the gods of Greek mythology, titanium is the heaviest light metal at 4.5–4.8 g/cm3 (by comparison: aluminum is 2.7 g/cm3, and steel is 7.5–7.8 g/cm3). And its properties are impressive: It is corrosion resistant, especially tough and durable. Even in a concentration of only 0.01–0.1 percent by weight, it gives steel exceptional toughness, strength and ductility. Where is titanium used? Titanium is frequently used in medical and dental technology as a biomaterial for implants and other medical products. It seldom causes rejection reactions and allows bone ongrowth. But there are other uses, as well: For tools or components that require protection from corrosion or in aircraft construction. Here, it is used for parts subject to especially heavy stress that must nonetheless be light (such as turbine blades). Many other products employ titanium, as well, from protective clothing to sports equipment and jewelry and even cosmetics. Where can it be found? Titanium is found in the earth’s crust and, apart from a few exceptions, only in combination with oxygen as an oxide. It is by no means scarce. With a content of 0.565 percent, it is the ninth most common element in the continental crust. Usually, however, it is found only in a low Hip joint prosthesis with socket and head BEYOND SURFACES 01|2019
High-purity titanium (99.999%) with a visible crystalline structure Photo: Alexander C. Wimmer concentration. The principle conditions that allow extraction of larger amounts are found in Australia, Scandinavia, North America, the Urals, Malaysia and Paraguay. Is titanium expensive? Titanium is about 35 times more expensive than common steel alloys and about 200 times more expensive than crude steel. In the traditional process, known as the Kroll process, ilmenite (titanium iron ore, FeTiO3) or rutile (TiO2) are treated at temperatures of greater than 1,000 °C with chlorine gas, other volatile chlorides and liquid magnesium. This causes the formation of blocks of pure, solid titanium. The process is extremely complex, requires a great deal of energy and is about 10,000 times less efficient than that used for making iron. Progress is expected with a new process devel- oped in 2015 by the Stanford Research Institute at Stanford University in Menlo Park (USA): The energy of a plasma arc is used to split the titani- um-chlorine bonds in titanium chloride obtained from titanium ore. The result here is titanium vapor, which quickly solidiﬁ es and forms titanium powder. The signiﬁ cantly lower amount of time and resources consumed provides a noticeable reduction in manufacturing costs. Spot on 35 Ilmenite is one of the most important sources of titanium oxide. Quartz with rutile inclusions: Rutile is a commonly occurring mineral from the class of “Oxides and Hydroxides” with the chemical formula TiO2, and it is called titanium dioxide in chemical terms. BEYOND SURFACES 01|2019
36 FIVE MINUTES FOR A TRULY HOT TOPIC “My research and I – that’s a little bit like neutral Switzerland between academia and industry,” says Edward Jonas Gildersleeve V, winner of the Oerlikon Metco Young Professional Award 2018, as we meet with him for an interview. The trip to Switzerland and Oerlikon Metco in Wohlen was the young New Yorker’s first journey abroad, as well as a further highlight of the OMYPA. by Agnes Zeiner The late-winter weather in Switzer- land stood in stark contrast to the warmth and sunshine of Orlando, Florida, home to the ﬁ rst OMYPA. Ed Gildersleeve, who is writing his dis- sertation at the Center for Thermal Spray Research of the Department of Materials Science and Engineering at Stony Brook University in New York, recalls: “In May 2018, I presented my work at the ITSC, or International Thermal Spray Conference and Exposition, in Orlando, Florida. They gave me exactly ﬁ ve minutes!” Gildersleeve mastered the challenge and won the Oerlikon Metco Young Professional Award. BEYOND SURFACES 01|2019 “At the Center for Thermal Spray Research, we have constructed a gas combustion burner rig on which we can simulate the effects that takeoffs and landings have on jet engines. Among other things, we are also using it to test thermal barrier coatings (TBC), which are a focus of my research. For my presentation at the ITSC, I concentrated on only one aspect and chose the topic of CMAS.” (CMAS stands for debris containing primarily calcium, magnesium, aluminum, and silicon.) “Briefly, this deals with the question of what changes contaminants in the combustion gas and the ambient air cause in the TBC coatings over a certain operating period and temperature. The reason is that the turbines heat up to as much as 1,200 °C, which causes contaminants like these to melt and affect the coatings. My research examines how certain combinations of materials behave under operating conditions over a specific period of time.” That behavior, of course, is what most interests the young materials scientist. He is concerned not with finding the perfect material for an application, but rather with understanding how a material reacts under certain conditions and over a given period of time so as to draw conclusions for the process (failure mechanisms). “For me, what I do is almost intui- tive – nonetheless, I am moving in directions that no one else has yet thoroughly pursued. This is an aid to other people in their work, whether it be research or in industry, because what we publish is utilized by both sides. It’s both exciting and very enriching at the same time,” relates Gildersleeve. Does he personally feel more drawn toward industry in the final analysis, or will he remain true to his roots in research? That is something the OMYPA winner does not yet know: “What I need to do now is get my doctoral work finished. Then we’ll see. I find both options appealing!”
Technology & Innovation 37 Oerlikon Metco Young Professional Award (OMYPA) The OMYPA was launched by Prof. Dr.-Ing. Kirsten Bobzin of the University of Aachen. It is funded by Oerlikon Metco and organized by the German Welding Society (DVS) and ASM International. It aims to acknowledge students, doctoral candidates and scientists from all over the world, and to encourage new talent to engage in the advancement of surface engineering. Award contestants are students who are currently in their graduate year of university and have prepared an abstract on their thermal spray research. The submitted abstracts are evaluated by an interna- tional team of thermal spray professionals from both academia and industry. The abstracts selected are presented by the finalists at the ITSC, where they are evaluated and scored for originality, experimental and research results and presentation style.
38 Technology & Innovation A COMPACT FUTURE When Oerlikon puts a new product or technology on the market, it is not thanks to a few clever inventors ensconced in a small room somewhere. Quite the contrary: they keep an eye out for customers’ experiences, which form the basis for innovation. This was the case as well with the recent development from Oerlikon Metco: a totally new type of machine for thermal coatings. In an effort to gain a better understanding of requirements, a meticulous pro- cess was employed to survey more than 45 customers. They shared their vision for the future of thermal spray coatings with the developers, explained their challenges and talked about their needs. Based on this invaluable input, Oerlikon Metco developed an unprecedented system: Surface One. Delighted customers This first machine for thermal spray coatings integrates three spray pro- cesses, a spray gun and part handling system, and powder feeders into one compact unit. The Surface One has generated excitement on the market accordingly. Nicholas Lindroos from TKM TTT Finland OY, one of the first people to experience a machine like this live, remarks: “For us, the best Surface One possibility is that we can change very fast to different applica- tions and different powders.” And Joe Martin from Chromalloy in New York expressed that he is “very impressed BEYOND SURFACES 01|2019 that it was actually put together in a one-pickup unit.” Ansar Syed-Asif from the German Aerospace Center puts it succinctly: “Oerlikon Metco is the leading com- pany in this area and a good partner, and together with them, we would like to bring the whole technology into the future.”
SURFACE ONE … is so compact that it even fits in a transport container. It takes up much less space on the production floor and can easily be relocated to a different site. scores high marks with a standardized, modular and configurable design. This speeds up delivery by 30% and installation by 80%, which dramatically reduces the duration of interruptions in production. enables accelerated production planning because now, coating recipes and operating configurations can be transferred from one machine to another worldwide. This ensures reliable and reproducible coatings everywhere throughout a corporation. enables intuitive and configurable handling with its Clarity user interface and guides operators through the process. These aspects simplify production, avoid errors and provide greater efficiency in operation. is matched to the requirements of Industry 4.0 and the IIoT1 and can be integrated with ease into any production environment in order to provide even better production process control. can easily be adapted to various requirements, which minimizes production interruptions. Find the video and more information at www.oerlikon.com/pages/surface-one 1 Industry 4.0 is a term that was introduced by the German government to refer to the trend to automation and data exchange in the context of production technol- ogies that enable what is know as a “smart factory”. The “Industrial Internet of Things” (IIoT) is part of Industry 4.0, in which cyber-physical systems and devices com- municate and work together with one another as well as with humans in real time. A persuasive solution Oerlikon Metco’s “intelligent factory of the future” has persuaded not only customers, but also the Red Dot Design Awards jury and the International Design Excellence Awards (IDEA), who have given the new system accolades for its product design. Its success is also conﬁ rmed by the fact that since the market launch just shy of one year ago, more than ten machines have already been sold. In fact, due to the high demand, Oerlikon Metco has invested in a new production facility speciﬁ cally for the Surface One.
40 Technology & Innovation Trade show dates In the upcoming months, Oerlikon will again be represented at important trade fairs dealing with surface solutions and additive manufacturing. We look forward to your visit to our booth! Europe Asia June 17–23 International Paris Air Show Paris, France June 19–22 INTERMOLD Nagoya 2019 Nagoya, Japan June 18–21 EPHJ-EPMT-SMT Geneva, Switzerland June 25–27 Rapid.Tech Erfurt, Germany Sept 3–6 SPE Offshore Europe Aberdeen, UK Sept 9–13 EUROCORR Seville, Spain Sept 16–21 EMO Hannover Hannover, Germany July 2–5 MTA Vietnam 2019 HCMC, Vietnam Nov 20–23 Metalex 2019 Bangkok, Thailand Americas June 11–13 OMTEC Chicago (IL), USA Sept 24–26 Alihankinta Subcontracting Sept 25–28 NASS Oct 7–9 Oct 16–23 Nov 5–8 Tampere, Finland Aachen Colloquium Automobile and Engine Technology Aachen, Germany K-Messe Düsseldorf, Germany Blechexpo Stuttgart, Germany Nov 12–15 Elmia Subcontractor Jönkoping, Sweden Nov 13–14 Metalmadrid 2019 Nov 19–22 Madrid, Spain FormNext Frankfurt, Germany Nov 21 Swiss Innovation Forum Basel, Switzerland Sept 30 – Oct 3 Oct 1–3 Oct 22–24 Nov 11–14 Dec 12–14 Dec 19–21 Chicago (IL), USA CMTS Toronto (ON), Canada NADCA Cleveland (OH), USA Southtec Greenville (SC), USA Fabtech Chicago (IL), USA PRI Indianapolis (IN), USA PowerGen New Orleans (LA), USA BEYOND SURFACES 01|2019 BEYOND SURFACES 01|2019
3rd munich technology conference on additive manufacturing MTC3 CONFERENCE, WORKSHOPS, START-UP CHALLENGE Accelerating the tempo of industrialization Those who recognize and take advantage of the possibilities offered by additive manu- facturing can secure a decisive advantage for both themselves and their customers. The 3rd Munich Technology Conference on Additive Manufacturing (MTC3) will provide you with an overview of the latest developments and applications as well as information on the state of the art and its future. How can industry, government and academia become better networked to accelerate the industrialization of this exciting technology? Take part in the exchange of ideas and get involved in the discussion as prestigious global decision-makers and leaders gather from October 8–10, 2019 in Munich, Germany. You can find more information at: www.munichtechconference.com October 8 Young companies from the 3D printing sector and potential investors meet at the Start-up Challenge in the evening – don’t miss it! October 9 Join the conference and learn in specific panels about trends in hardware, software and materials. October 10 Dive even deeper into the world of addi- tive manufacturing – in individual work- shops on topics that move the industry. BE PART OF IT!