MUlti Layer coatings for additive components in the automotiVE sector

MUVE aims to demonstrate the applicability of multilayer
coatings to additively manufactured (AM) components
made of aluminium alloy and stainless steel. Two coated
prototypes will be produced: (i) AlSi10Mg highperformance
motorbike steering plate, and (ii) AISI 316L
screw, with internal channels for cooling/lubricant flow.
Complete microstructural and micro-mechanical
characterization of the prototypes will demonstrate the
effectiveness of the multilayer, consisting of an
electroless Ni-P interlayer and a diamond-like carbon
topcoat (DLC). Ni-P, deposited from the liquid phase,
provides the ability to coat complex geometries with
uniform thickness and to compensate surface and
surface-connected defects (typical of AM processes) as
well as load support. DLC provides high wear resistance
combined with low friction, a unique combination typical
of this class of vapor-deposited thin layers.
The deposition of the whole multilayer, and the barrel
finishing procedures included in the deposition cycle, will
be carried out in an industrial environment. The
Consortium of Partners involved in MUVE provides the
expertise and the facilities to cover all the aspects of the work: from prototype design to Powder Bed Fusion-Laser
Based (PBF-LB) printing, to surface modification, and
finally to advanced microstructural and micro-mechanical
testing for performance assessment. The whole workflow
of MUVE closely involves the use and the development of
digital tools: from prototype design to optimization and
monitoring of printing efficiency, to establishing the
correlations between multilayer deposition parameters,
microstructure, properties and performance.
MUVE builds on the results of previous projects, which
allowed to optimize the surface modification cycle and
assess the performance of samples and demonstrators
(TRL5): the aim of MUVE is to reach TRL7, demonstrating
the actual effectiveness of prototypes, selected and
designed to represent high-performance automotive
components.
MUVE will also extend beyond automotive and
motorsport, impacting on the whole value chain (VC) of
mechanical industry in the Emilia-Romagna (ER) region.
This VC covers 15% of the national mechanical industry,
generating 50% of regional exports thanks to other driving
sectors such as packaging and machine tools. The ER
region covers all the links in this VC, from AM to coating:
a sixfold increase in AM parts is expected by 2033, hence
a significant increase of the request for high-performance
components can also be expected, requiring tailored
surface modifications.
The knowledge basis of MUVE is firmly based on the
deliverables of WP1 and WP5 (Spoke 1), as referenced in
the proposal text. Moreover, MUVE brings together the
expertise of Spoke 1 and Spoke 3, exploiting green
manufacturing and green design to develop innovative
components made of sustainable materials, to support
the ecological transition.