Plenary Talk: New materials and manufacturing processes – key technologies of the industries of the future

Keynote Speaker: Prof. Dr. Dr. h.c. Rainer Gadow
Director of the Institute for Manufacturing Technologies of Ceramic Components and Composites, IMTCCC (Institut für Fertigungstechnologie keramischer Bauteile, IFKB), Universität Stuttgart.
Description: New materials concepts and their manufacturing technologies have achieved special interest in previous years in comparison to the coventional material groups. Complex sets of requirements cannot be fulfilled by any bulk material but the structural and functional properties are more and more realized by fiber, particulate and layer composite concepts. Fiber reinforced composites are key issues in light weight engineering. Advanced surface engineering and layer composites often combine extreme technical performance with competitive cost in processing and manufacturing. The high performance of novel ceramic nano composites and features nano structured materials with extreme hardness, toughness and abrasion resistance predestined this material class also for defence and advanced engineering applications. These ultra hard materials will be the state of the art in high end tools for extreme conditions. Near-net-shape manufacturing is mandatory for the manufacturing of complex shaped components by reasonable cost targets and for successful industrial product development. Ceramic composites near-net-shape forming technologies such as injection moulding, gel casting and slip casting have been developed as well as various axial and hot pressing techniques which lead to high performance materials at affordable production cost. Reinforced composite materials such as Polymer Matrix Composites, Metal Matrix Composites and Ceramic Matrix Composites will be extensively discussed especially with relevance on state-of-the-art applications in light weight engineering and extreme conditions.
Advanced surface coating technologies are essential to improve the performance and efficiency of engines, energy conversion systems, electrical engineering and biomedical applications. Advanced coating technologies such as air plasma and vacuum plasma spraying or supersonic flame spraying are high energetic processing technologies. Very thin coatings of various oxide based nanocomposites and cermets for tribological and further applications in automotive, aerospace and mechanical engineering for defence applications are achieved by supersonic flame spraying (HVOF and HVOLF) and high velocity suspension flame spraying (HVSFS). To optimize the intensive heat and mass transfer during such coating processes the plasma or HVOF spray torches require sophisticated robot control and steering systems to obtain reproducible, predictable and high quality results. Protective and functional coatings made by thermal spray technologies play an important role in various emerging markets.
 About the Speaker:Prof. Dr. Dr. h.c. Rainer Gadow is a full professor and managing director of the Institute for Manufacturing Technologies of Ceramic Components and Composites, IMTCCC (Institut für Fertigungstechnologie keramischer Bauteile, IFKB) at the Universität Stuttgart. After his graduation in chemistry he received a doctor’s degree in the field of fibre reinforced ceramics at the Universität Karlsruhe (T.H.), where he was a scientific co-worker at the Institute of Technical Chemistry. During this time he did his main research on fibre development with new materials and manufacturing technologies as well as surface technologies with high energetic coating processes, reinforced glasses, oxide and non-oxide ceramics as well as refractory metallurgical and ceramic coatings. After first functions in industry as head of the research and development department as well as managing director at W. Haldenwanger Technical Ceramics he took on several functions in the executive board of the company group of Deutsche Babcock Borsig AG as well as Balcke-Dürr AG. In 1995, he became managing director of the newly founded institute in Stuttgart. The IMTCCC focus on modern production engineering for ceramic parts and components and the precision finishing thereof. Another emphasis is on the connection of CAD based construction with modern forming and shaping processes including laser stereo lithography. In addition, surface engineering by means of thermal spraying and plasma processes, especially for the application of functional surfaces on light metal components, as well as fiber composites. Specific process automation, studies on organization and communication forms in companies and quality management and quality control methods and systems according to the standards of the international automotive industry adds important aspects to the material specific research areas.