ENDURANCE: Graphene based coatings for durable wear resistance low cost position sensors
Lead Research Organisation:
University College London
Department Name: Institute for Materials Discovery
Abstract
Developed by Prof. Choy, Aerosol Assisted Ion Deposition (AAID) is a novel, non-vacuum, cost effective and eco-friendly method for the non-line-of-sight deposition of both thin and thick coatings to 3D structure (non-conformal substrates) with control of structure and composition at the nanoscale. The fabrication of uniform graphene based nano-composite coatings, involves formulation of chemical precursors, which can be a solution or a suspension, and atomisation of the precursor to generate a finely charged aerosol. This allows control of the dynamics of droplets and their evaporation to form droplets consisting of polymeric ions, leading to the deposition of polymeric films incorporating with graphene based nanomaterials to form nanocomposite coatings with uniform and well-controlled structures in an open atmosphere.
Within the ENDURANCE project we will apply this technique for the development graphene based nanocomposite coatings on potentiometer wiper heads targeting excellent conductivity between 1 and 300 ohm/square and wear resistance.
Key challenges to be addressed in our research include:
(1) Graphene interfaces: Limited knowledge of wear properties for graphene to graphene material contacts - we will explore the relationships between graphene coating formulation, chemical / physical properties and the wear properties at graphene to graphene interfaces;
(2) Coating stability: Achieving complete polymerisation during cure thereby enabling long term coating stability - we will explore the relationships between graphene ink formulation and cure properties enabling optimisation of rapid and stable cure;
(3) Coating surfaces: Ensuring graphene is concentrated at the coating surface to enable the surface properties to be realized- we will assess the feasibility to utilise electrostatic (repulsion) and formulation density to promote surface aggregation of graphene;
(4) Coating adhesion: Graphene traditionally has poor adhesion to material surfaces thereby limited coating wear stability - we will explore coating formulations, substrate surface treatments and layer thickness to improve adhesion and wear performance; and
(5) Conductivity: High conductivity requires excellent connectivity between graphene layers which may be difficult to achieve - we will explore the addition of both conductive additives and surface treatments to promote coating conductivity.
Our research approach will follow three key phases (tasks):
Task 1. Formulation Screening: nano-composite ingredients will be screened (graphene, nano-tubes, surfactants, binders, cross linkers, solvents, lubricants etc...) using standard formulations to understand relationships between formulation, AAID processing, and coating properties and performance (adhesion, conduction, wear and cure)
Task 2. Coating formulation: different coating formulations will be investigated to achieve the target properties within the constraints of the material and processing requirements. A limited number of systems will be selected for further study.
Task 3. First generation ink development: selected coating formulations will undergo a number of development cycles to optimise consistency, reliability, wear, rheology, cure etc. Substrate chemical (etching) & physical surface modification strategies will be considered to improve coating adhesion. A tribometer test rig will be used to assess wear and coating adhesion.
We will also support investigation of graphene to graphene interface wear properties using statistical analysis methods (performance analysis) and analysis of wear samples to understand the wear mechanisms.
Within the ENDURANCE project we will apply this technique for the development graphene based nanocomposite coatings on potentiometer wiper heads targeting excellent conductivity between 1 and 300 ohm/square and wear resistance.
Key challenges to be addressed in our research include:
(1) Graphene interfaces: Limited knowledge of wear properties for graphene to graphene material contacts - we will explore the relationships between graphene coating formulation, chemical / physical properties and the wear properties at graphene to graphene interfaces;
(2) Coating stability: Achieving complete polymerisation during cure thereby enabling long term coating stability - we will explore the relationships between graphene ink formulation and cure properties enabling optimisation of rapid and stable cure;
(3) Coating surfaces: Ensuring graphene is concentrated at the coating surface to enable the surface properties to be realized- we will assess the feasibility to utilise electrostatic (repulsion) and formulation density to promote surface aggregation of graphene;
(4) Coating adhesion: Graphene traditionally has poor adhesion to material surfaces thereby limited coating wear stability - we will explore coating formulations, substrate surface treatments and layer thickness to improve adhesion and wear performance; and
(5) Conductivity: High conductivity requires excellent connectivity between graphene layers which may be difficult to achieve - we will explore the addition of both conductive additives and surface treatments to promote coating conductivity.
Our research approach will follow three key phases (tasks):
Task 1. Formulation Screening: nano-composite ingredients will be screened (graphene, nano-tubes, surfactants, binders, cross linkers, solvents, lubricants etc...) using standard formulations to understand relationships between formulation, AAID processing, and coating properties and performance (adhesion, conduction, wear and cure)
Task 2. Coating formulation: different coating formulations will be investigated to achieve the target properties within the constraints of the material and processing requirements. A limited number of systems will be selected for further study.
Task 3. First generation ink development: selected coating formulations will undergo a number of development cycles to optimise consistency, reliability, wear, rheology, cure etc. Substrate chemical (etching) & physical surface modification strategies will be considered to improve coating adhesion. A tribometer test rig will be used to assess wear and coating adhesion.
We will also support investigation of graphene to graphene interface wear properties using statistical analysis methods (performance analysis) and analysis of wear samples to understand the wear mechanisms.
Planned Impact
Scientific Impact: our group will create scientific impact in five key areas: i) we will better understand the factors influencing wear properties at graphene to graphene interfaces enabling the development of new materials capitalizing on the benefits of graphene; ii) we will better understand the factors that influence and improve the adhesion of graphene composite materials to substrates enabling their use as robust coatings; iii) we will better understand how to formulate wear resistant and conductive graphene based nano-composite materials thereby open new lines of applied research; and iv) we will better understand how to fully cure graphene based inks thereby enabling long term stability of the coating properties. This scientific knowledge will underpin key technology impacts.
Technology Impact: ENDURANCE will demonstrate feasibility for highly innovative graphene enabled Linear Sensors (potentiometer + wiper) and Encoder Sensors (Encoder Unit + Wiper). The sensor designs will incorporate wear resistant graphene based resistive, conductive and barrier coatings enabling breakthrough advancements in sensor design, manufacture and performance: Wiper: will utilise wear resistant conductive graphene based nanocomposite coatings enabling replacement of palladium based wiper heads and leading to significant cost savings for manufacture (>50%). Potentiometer: will utilise atomically smooth, chemically inert, mechanically durable and lubricating graphene based resistive track to achieve a breakthrough in durability and lifetime (>10 million cycles) and sensor accuracy (<0.5% uncorrelated linearity) whilst realising cost savings by enabling fully printed units (>25%). Encoder Unit: will utilise wear resistant conductive barrier coatings for replacement of existing gold and nickel materials thereby enabling fully printed units with exceptional resolution (from 6 to 40+ pulse sensors) and lower manufacturing costs (>26%).
The ENDURANCE sensors represent a highly disruptive technology for the position sensor market combining the exceptional accuracy and durability of contactless sensors with the low cost of contact based sensors; thereby exceeding all commercially available sensor designs and meeting all key user requirements. This technology will underpin key market impacts.
Market Impact: Having a performance comparable to non-contact devices and a cost lower than contact based systems, the technology will enable clearly differentiated and cost competitive solutions (even against suppliers from Asia). Lower device costs will also enable greater use throughout the car at minimal extra cost to the customer, satisfying the demand for intelligence as standard. Since the performance and cost advantages are enabled only through use of the highly innovative graphene based materials the technology will be difficult to imitate by foreign competitors. The simplicity of device design will enable rapid customisation for different applications and market sectors. Excellent performance features (and lifetime) will also reverse the trend to non-contact based systems.
Technology Impact: ENDURANCE will demonstrate feasibility for highly innovative graphene enabled Linear Sensors (potentiometer + wiper) and Encoder Sensors (Encoder Unit + Wiper). The sensor designs will incorporate wear resistant graphene based resistive, conductive and barrier coatings enabling breakthrough advancements in sensor design, manufacture and performance: Wiper: will utilise wear resistant conductive graphene based nanocomposite coatings enabling replacement of palladium based wiper heads and leading to significant cost savings for manufacture (>50%). Potentiometer: will utilise atomically smooth, chemically inert, mechanically durable and lubricating graphene based resistive track to achieve a breakthrough in durability and lifetime (>10 million cycles) and sensor accuracy (<0.5% uncorrelated linearity) whilst realising cost savings by enabling fully printed units (>25%). Encoder Unit: will utilise wear resistant conductive barrier coatings for replacement of existing gold and nickel materials thereby enabling fully printed units with exceptional resolution (from 6 to 40+ pulse sensors) and lower manufacturing costs (>26%).
The ENDURANCE sensors represent a highly disruptive technology for the position sensor market combining the exceptional accuracy and durability of contactless sensors with the low cost of contact based sensors; thereby exceeding all commercially available sensor designs and meeting all key user requirements. This technology will underpin key market impacts.
Market Impact: Having a performance comparable to non-contact devices and a cost lower than contact based systems, the technology will enable clearly differentiated and cost competitive solutions (even against suppliers from Asia). Lower device costs will also enable greater use throughout the car at minimal extra cost to the customer, satisfying the demand for intelligence as standard. Since the performance and cost advantages are enabled only through use of the highly innovative graphene based materials the technology will be difficult to imitate by foreign competitors. The simplicity of device design will enable rapid customisation for different applications and market sectors. Excellent performance features (and lifetime) will also reverse the trend to non-contact based systems.
People |
ORCID iD |
Kwang-Leong Choy (Principal Investigator) |
Publications
Brabazon, D
(2018)
Commercialization of Nanotechnologies-A Case Study Approach
Chen S
(2021)
The importance of particle dispersion in electrical treeing and breakdown in nano-filled epoxy resin
in International Journal of Electrical Power & Energy Systems
Sun K
(2019)
Negative permittivity derived from inductive characteristic in the percolating Cu/EP metacomposites
in Journal of Materials Science & Technology
Description | Adherence and robust graphene based coatings with well controlled structure and composition have been successfully deposited by UCL using a novel and non vacuum Aerosol Assisted Ion Deposition onto BOSCH and PVI wipers. The coated wipers are wear resistant survived more than 1.5 million test cycles and the test is still on going. The research output has led to UCL participating in the H2020 Marketplace project (€ 9, 189 778) to translate industrial problems into materials modelling for increased industrial innovation (https://cordis.europa.eu/project/id/760173) |
Exploitation Route | The industrial partner, PVI is very keen to scale up the AAID technology for the mass production of Low Cost Position Sensors. |
Sectors | Aerospace Defence and Marine Chemicals Digital/Communication/Information Technologies (including Software) Electronics Energy Environment Healthcare Manufacturing including Industrial Biotechology Security and Diplomacy Transport |
Description | The deposition technology has been adapted and exploited for the deposition of nanocarbon based coatings for healthcare and biomedical applications. Furthermore, the research output has aslo led to UCL participating in the H2020 Marketplace project (€ 9, 189 778) to translate industrial problems into materials modelling for increased industrial innovation (https://cordis.europa.eu/project/id/760173). Most recently the deposition technology is being adapted for clean energy application in a new EU NEXTCCUS project for the fabrication of next generation electrochemical materials for sustainable direct CO2 capture and utilization/storage as clean solar fuel. |
Sector | Chemicals,Energy,Healthcare,Pharmaceuticals and Medical Biotechnology |
Impact Types | Societal |
Description | ERANET ACT 3: Accelerating CCUS Technologies |
Amount | € 2,800,000 (EUR) |
Funding ID | 5975830 |
Organisation | Department for Business, Energy & Industrial Strategy |
Sector | Public |
Country | United Kingdom |
Start | 09/2021 |
End | 09/2024 |
Description | GrapheneSens |
Amount | € 50,000 (EUR) |
Funding ID | 762394 |
Organisation | European Commission H2020 |
Sector | Public |
Country | Belgium |
Start | 02/2017 |
End | 07/2017 |
Description | H2020 Sedna |
Amount | € 6,500,000 (EUR) |
Funding ID | 723526 |
Organisation | European Commission |
Sector | Public |
Country | European Union (EU) |
Start | 04/2017 |
End | 04/2020 |
Description | HIGH-PROSPECTS |
Amount | £1,245,338 (GBP) |
Funding ID | 102470 |
Organisation | Innovate UK |
Sector | Public |
Country | United Kingdom |
Start | 11/2016 |
End | 10/2018 |
Description | High-ACCuracy printed electronics down to µm size, for Organic Large Area Electronics (OLAE) Thin Film Transistor (TFT) and Display Applications. |
Amount | € 5,931,888 (EUR) |
Funding ID | 862410 |
Organisation | European Commission H2020 |
Sector | Public |
Country | Belgium |
Start | 03/2020 |
End | 10/2023 |
Description | Marketplace |
Amount | € 8,147,525 (EUR) |
Funding ID | 760173 |
Organisation | European Commission H2020 |
Sector | Public |
Country | Belgium |
Start | 01/2018 |
End | 12/2022 |
Description | Multifunctional coatings |
Amount | £106,000 (GBP) |
Organisation | Defence Science & Technology Laboratory (DSTL) |
Sector | Public |
Country | United Kingdom |
Start | 09/2018 |
End | 09/2021 |
Title | A novel deposition method applicable for biomedical applications. |
Description | A novel method and tooling for depositing functional layers for dialysers for the effective removal of toxin including protein bound toxin. |
Type Of Material | Improvements to research infrastructure |
Year Produced | 2018 |
Provided To Others? | No |
Impact | An innovative and cost-effective method for the removal of protein bound toxin during dialysis. |
Description | Graphene based coatings and applications |
Organisation | AzTrong Inc. |
Country | United States |
Sector | Private |
PI Contribution | Novel and cost-effective superthin/thin film deposition of graphene by UCL using Chemical Vapour Deposition based methods. |
Collaborator Contribution | Application evaluation and exploitation of graphene thin films for structural, functional and biomedical applications. |
Impact | Multi-disciplinary collaboration and working towards joint grant applications and exploring venture funding for technology exploitation. |
Start Year | 2016 |
Description | Nanocomposite coatings for aviation applications. |
Organisation | CAV Aerospace |
Country | United Kingdom |
Sector | Private |
PI Contribution | Materials discovery and innovative and cost-effective manufacturing of high performance nanocomposite coatings by UCL. |
Collaborator Contribution | Exploitation of nanocomposite coatings by CAV Aerospace for aviation applications. |
Impact | Multidisciplinary collaboration which has led to a joint grant application to develop a prototype demonstrator. |
Start Year | 2016 |
Description | Nanocomposite coatings for engineering applications |
Organisation | Cytec Industries |
Department | R&D |
Country | United States |
Sector | Private |
PI Contribution | The development of robust and cost-effective multifunctional nanocomposite coatings for automotive applications. |
Collaborator Contribution | *Formulated coating precursor *Established the window of processing conditions for multifunctional coatings *Successfully fabricated and tested the robust multifunctional nanocomposite coatings which fulflling the requirements of industrial partners |
Impact | The has led to H2020 project submission in 2019 for the industrial scale up and pilot project. |
Start Year | 2018 |
Description | Nanocomposite coatings for functional applications |
Organisation | Centre for Process Innovation (CPI) |
Country | United Kingdom |
Sector | Private |
PI Contribution | The materials formulation and processing of nanocomposite films for functional applications. |
Collaborator Contribution | Scale up processing using the formulation developed by the UCL team. |
Impact | Agreement to enter into joint grant application to Innovate UK. |
Start Year | 2018 |
Description | Thin films and Nanocomposites for structural and functional applications. |
Organisation | William Blythe Ltd |
Country | United Kingdom |
Sector | Private |
PI Contribution | Materials formulation, functionalisation and applications with end-users. |
Collaborator Contribution | Materials supplier within the value chain. |
Impact | Multidisciplinary collaboration. |
Start Year | 2018 |
Title | In-situ formation of nanocmposites |
Description | A novel and cost-effective in-situ processing of dielectric nanocomposites with well controlled structure and composition, as well as minimising the agglomeration of nanoparticles in composites. |
IP Reference | |
Protection | Protection not required |
Year Protection Granted | 2017 |
Licensed | Commercial In Confidence |
Impact | Simplfying the processing of nanocomposites. The fabricated method is not only applicable for dielectric application but also for other structural, functional and biomedical applications. |
Title | Medical device -dialyser |
Description | Received Therapeutic Acceleration Support (TAS) Fund of £74840 to perform a proof of concept of novel and high performance coated haemodialysis dialysers designed to adsorb uraemic toxins. |
Type | Therapeutic Intervention - Medical Devices |
Current Stage Of Development | Initial development |
Year Development Stage Completed | 2019 |
Development Status | Under active development/distribution |
Impact | The novel coated dialyser has generated interests from 3 international dialyser manufacturers that wish to collaborate with us and evaluate our coated dialysers. |
Description | 2020 The 10th International Conference on Key Engineering Materials |
Form Of Engagement Activity | Participation in an activity, workshop or similar |
Part Of Official Scheme? | No |
Geographic Reach | International |
Primary Audience | Professional Practitioners |
Results and Impact | The purpose of The 10th International Conference on Key Engineering Materials (ICKEM 2020) is to bring together researchers, engineers and practitioners interested in the whole range of fields related to the materials that underpin modern technologies |
Year(s) Of Engagement Activity | 2020 |
URL | https://www.buildup.eu/en/events/10th-international-conference-key-engineering-materials-ickem-2020 |
Description | 5th International Conf. on Advanced Manufacturing and Materials (ICAMM) 2021, Macau, China, Nov. 2021 |
Form Of Engagement Activity | A talk or presentation |
Part Of Official Scheme? | No |
Geographic Reach | International |
Primary Audience | Professional Practitioners |
Results and Impact | ICAMM 2021 focuses on the advanced manufacturing and materials research. The applications of advanced manufacturing and materials to such domains as Multi-scale and/or Multi-disciplinary Approaches, |
Year(s) Of Engagement Activity | 2021 |
URL | http://www.wikicfp.com/cfp/servlet/event.showcfp?eventid=127270©ownerid=13881 |
Description | Innovation in materials design and processes for delivering high performance nanostructured films and nanocomposite coatings, International Conference on Nanomaterials and Biomaterials (ICNB 2017) 11-13 December 2017 in Amsterdam |
Form Of Engagement Activity | Participation in an activity, workshop or similar |
Part Of Official Scheme? | No |
Geographic Reach | International |
Primary Audience | Professional Practitioners |
Results and Impact | The study of all materials requires a multi-tool approach to analysing and characterising the material as well as its interactions and function. It is by using these orthogonal approaches that the best discoveries are made and data turns into knowledge for the benefit of the science. ICNB 2017 would bring together researchers from academia and industry with practitioners in materials characterisation, including instrument manufacturers and developers, to open dialogues about new approaches and technological innovation in the field of Nanomaterials and Biomaterials. |
Year(s) Of Engagement Activity | 2017 |
URL | http://www.icnb.org/ |
Description | Invited talk on "High Performance Nanostructured Coatings and their Applications" at XXVII Materials Research Congress, Cancun, Mexico, August 2018 |
Form Of Engagement Activity | Participation in an activity, workshop or similar |
Part Of Official Scheme? | No |
Geographic Reach | International |
Primary Audience | Professional Practitioners |
Results and Impact | A core mission of the Materials Research Society is to promote leading-edge research on materials around the world. The Materials Research Society (MRS) and the Sociedad Mexicana de Materiales (SMM) worked together on this global effort by growing the International Materials Research Congress (IMRC) held annually in Cancun, Mexico. The IMRC offered a range of symposium topics of interest to the materials research community at large. It has become a popular conference destination with about 1,700 attendees from nearly 60 countries in 2018. |
Year(s) Of Engagement Activity | 2018 |
URL | http://www.mrs-mexico.org.mx/imrc2018/ |
Description | Keynote paper at 21st International Conference on Advances in Materials & Processing Technologies, Dublin, Ireland, 4th -7th September 2018 |
Form Of Engagement Activity | Participation in an activity, workshop or similar |
Part Of Official Scheme? | No |
Geographic Reach | International |
Primary Audience | Professional Practitioners |
Results and Impact | The AMPT conference series provides a forum for academics, researchers, and practicing engineers to meet and exchange innovative ideas and information on all aspects of material processing technologies |
Year(s) Of Engagement Activity | 2018 |
URL | http://ampt2018.org/ |
Description | The 7th Annual World Congress of Nano Science & Technology-2017 |
Form Of Engagement Activity | Participation in an activity, workshop or similar |
Part Of Official Scheme? | No |
Geographic Reach | International |
Primary Audience | Professional Practitioners |
Results and Impact | The 7th Annual World Congress of Nano Science and Technology-2017 (Nano S&T-2017) was held in Japan during October 24-26, 2017. It covers all frontier topics in advanced nanomaterials, nanoelectronics, applications of nanotechnology, nanomedicine and biomaterials, etc. The aim of the conference was to bring together leading scientists, researchers, engineers, practitioners, technology developers and policy makers from multidisciplinary research and application areas to exchange information on their latest research progress and innovation, to discuss the benefits of Nanotechnology and materials science in their research and development efforts to advance the networking, and collaborating between different academia, research and market leaders in the field. Participants from the top international academic, government and private industry labs of different disciplines participated in Nano S&t-2017 to identify new technology trends, development tools, R&D collaborations, and commercialization partners. It provided an unprecedented opportunity and effective platform for institutions and industries to share ideas and discover innovation in the area of nanotechnology and develop new business opportunities. 400+ Oral Presentations Covering the Hot Topics and Cutting-Edge Technology in the Field of Nanoscience and Nanotechnology and 50+ Posters Demonstrating. There were expressions of interests in the work of Professor Choy's group in using nanocomposite coating for high voltage dielectric breakdown as well as wider structural and functional applications. |
Year(s) Of Engagement Activity | 2017 |
URL | http://www.bitcongress.com/nano2017/RenownedSpeakers.asp |