Materials Design

Material design - from thermodynamics to processed material

After evaluation and consideration of the requirement profile, our material design starts with the calculation of the thermodynamic state of alloy systems by using Thermo-Calc software to predict:

  • Phase diagrams as well as the proportions and compositions of the individual phases
  • Transformation temperatures and solubility limits
  • Physical properties.

From these predictions, the next step is to derive predictions of the property profile and suitability of the proposed material composition using our empirical knowledge, utilizing empirical correlations, and increasingly by applying AI methods. Material combinations that appear interesting are validated experimentally in the final step. For this purpose, we use self-developed system technology and methodology for laser cladding for material synthesis. This allows us to optionally mix up to eight different powders and wires with different compositions (pure elements or master alloys) in-situ and thus apply defined alloy compositions or variations efficiently and reproducibly in graded bar samples. Typically, each of these bar samples can contain up to six alloy compositions. These can then be analyzed in terms of their structure and properties in a time-saving manner. If necessary and to take into account aspects of processability, cost or sustainability, the material design can be refined in further iteration stages according to your requirements.

Novel high-performance materials

In our material design offering, a particular focus is on the development of novel high-performance materials and coatings for use under extreme environmental conditions. By extreme conditions we mean, among other things, high or low temperatures, oxidative as well as corrosive environmental conditions, high static and cyclic loads as well as tribological stresses. We support you in adapting high-strength steels, aluminum, titanium and nickel materials to modern manufacturing processes, such as 3D printing, laser cladding or thermal spraying. Continue to benefit from our expertise in the development of new materials and processes for sustainable mobility and energy generation. For example, we are developing innovative ideas for new bearing materials for wind turbines and marine propulsion systems as well as material solutions for turbines using alternative fuels such as hydrogen. We also take into account the latest material concepts such as that of so-called high entropy alloys (HEA).

Sustainable materials production and processing

Sustainability aspects are of overriding importance for current and future material developments. Our offer on process-adapted material design therefore includes the consistent consideration of aspects of energy and material efficiency in synthesis and processing, material criticality and environmental compatibility or recyclability. We offer solutions for the partial or even complete replacement of critical alloy components such as cobalt or tungsten. Furthermore, we are working on the development of “composition tolerant“ materials and coatings that allow the use of recycled raw material and feedstock.