nanodiamond composites with enhanced thermal and
TRANSCRIPT
Advanced Engineering UK 2016
Netcomposites Forum
Gavin Farmer, Carbodeon
NanoDiamond Composites With Enhanced Thermal and
Mechanical Properties:
“Hard as Hell, but Cooler”
@carbodeon @ndplating Carbodeon Ltd. Oy.
Driving Technology
• uDiamond® NanoDiamonds
• Production from detonation stage
onwards
• Industrial supplies with established
accounts
• Continuous development of new
nanodiamond grades/ variants
• Applications development to support
new business in nanodiamond material
sales
• Nicanite® Carbon Nitride
HQ in Finland, Helsinki Region
Established 2006
Sales on 5 continents
Material selection: Compromise…..
Next gen.
product specsNot strong
enough
Too
brittle
Thermal
properties
Regulatory
Issues
Doesn’t fit
manufacturing
Other
problems
Too
expensive
Material selection: Compromise…..
Optimised
properties,
process, cost.
Base Material
Something
Extreme!
Selected ratio
Material design: Combine, Optimise……..
….. Property Combination + “NanoScale Effect”
Carbodeon NanoDiamond –
Extreme Material.
Strength
Hardness
Surface
Friction
Chemically
Inert
Optical
Properties
Dielectric
Thermal
Conductivity
With some unusual combinations
NanoComposite Requirements
Improve property A
without compromising
property B
in parent material X……..in our existing process
“thermal
conductivity,
and electrical
isolation”
“more power and
better economy”
“less energy and
more light”
“wear, and corrosion
resistance”
“faster, and
cheaper”
“lighter, but with the
same failure modes”
“better polished finish
same material
removal”
NanoComposite Requirements
Improve property A
without compromising
property B
in parent material X……..in our existing process
“thermal
conductivity,
and electrical
isolation”
“more power and
better economy”
“less energy and
more light”
“wear, and corrosion
resistance”
“faster, and
cheaper”
“lighter, but with the
same failure modes”
“better polished finish
same material
removal”
(Almost) Never the
same question twice!
The Nanocomposite Challenge
Parent Materials
Nanomaterials
Implementation
Practicality
Processing Methods &
Supply Chain
Nanodiamond Materials
Detonation Synthesised – 4-6 nm diamond particles
Proven industrial process: tonnes/ yr scale
With surface
functional groups
Graphitic facets Sp3 Diamond
Core
uDiamond® Portfolio – The Carbodeon Difference
Application-designed
• Tuned surface chemistry, no surfactants used
• Dispersion/Agglomeration control
• Dispersion media options
High purity
• ROHS compliant
REACH
• Member of Diamond Consortia
Active own application development
• Electroplating
• Thermal management
• Polymer composites
IPR
Reduced
consumption,
reproducibility
and cost
efficiency
COOH
OH
CONH2
H
NH2
HS
CH3OC
O2N
COOH
NH2
H
Z
Hydro
phili
city
R
Ole
ophilic
ity
uDiamond ® Amine P & D
New, patented highly zeta
positive nanodiamond powder
and dispersion with strong
particle interaction
• Fully amine functionalized
surface
• Hydrophobic
• Strong stability in solvents
• Launched 2015
Morphology
• Powders
• Dispersions in GBL, NMP,
NEP, DMA, more on the way
NH2
In-house and
customer application
development in
thermoplastics since
2013 and thermosets
since 2015
uDiamond® Portfolio
Options for surface chemistry and morphology
Powders - agglomerated clusters of NanoDiamonds in micron scale.
Used where no compatible solvent available, e.g. thermoplastics and
many thermosets
Suspensions – smaller agglomerates in liquid, easier to incorporate.
Dispersions – single digit 4-6 nm particles in stable dispersion
Very easy dispersion – direct mixing
Increased surface area
Low concentrations 0.05-1.0wt%, <1g/litre (in cases)
Morphology
NanoDiamond
Suspension
NanoDiamond
Powder
Detonation
Soot
NanoDiamond
Dispersion
5% 0.5%
Parent Materials
Metals
Thermosets
Thermoplastics
Coatings
Parent Materials - Metals
Nanodiamond suspension or dispersion added to plating solutions
Finer grain structure + embedded hard particles
1. Industrial machine parts with
hard chrome: durability
improved from 3.5 to 5.5 years
2. Gold plated electrical
connectors: wear performance
improved by 100%
3. Electroless nickel:
Abrasion resistance tripled
Parent Materials – Solvent or Aqueous Coatings
NanoDiamond powder, suspension, or dispersion
Hard particles bonded to parent material.
Polymer reinforced/ restructured at molecular scale
1. PTFE and FEP coatings –
aqueous and solvent.
Wear improvement up to 50%
Friction reduction up to 66%
Surface finish improved 85%
2. Consumer product: unnamed coating formulations on unnamed
products: Wear performance improved by >3X
Wear Properties – PTFE (Aqueous)
ND concentrations, in final coatings
• Agglomerating grade, 1 wt.%
• Single Digit grade, 0.1 wt.%
Wear properties studied up to 2000-3500 cycles
Up to 50% improvement in wear properties , up to 66% friction reduction
0
10
20
30
40
50
60
70
80
90
0 500 1000 1500 2000 2500 3000 3500 4000
Mass r
ed
ucti
on
(m
g)
Cycles
PTFE_REF - #1
PTFE_KT - #1
PTFE_Ktsingle - #1
REF. PTFE
1.0wt%
AGGLOM. ND
0.1wt%
SINGLE DIGIT
DISPERSION
Taber analyses
Wear Properties – PTFE (Aqueous)
ND concentrations, in final coatings
• Agglomerating grade, 1 wt.%
• Single Digit grade, 0.1 wt.%
Wear properties studied up to 2000-3500 cycles
Up to 50% improvement in wear properties , up to 66% friction reduction
0
10
20
30
40
50
60
70
80
90
0 500 1000 1500 2000 2500 3000 3500 4000
Mass r
ed
ucti
on
(m
g)
Cycles
PTFE_REF - #1
PTFE_KT - #1
PTFE_Ktsingle - #1
REF. PTFE
1.0wt%
AGGLOM. ND
0.1wt%
SINGLE DIGIT
DISPERSION
Taber analyses
Dispersion material –
Less is More!
Friction Properties – PTFE (Aq)
Friction tests with Allegro ND – not the latest single digit dispersion
ND concentrations varied between 0.1 to 3.0 wt.%
Significant improvements already with very low ND additions
66% reduction received with 2 wt.% ND concentration
0.000
0.020
0.040
0.060
0.080
0.100
0.120
0.140
0.160
1R 0.1 0.5 1.0 2.0 3.0
Fri
cti
on
co
eff
icie
nt
ND concentration (wt.%)
Allegro
Friction coefficient averages
Friction Properties – PTFE (Aq)
Friction tests with Allegro ND – not the latest single digit dispersion
ND concentrations varied between 0.1 to 3.0 wt.%
Significant improvements already with very low ND additions
66% reduction received with 2 wt.% ND concentration
0.000
0.020
0.040
0.060
0.080
0.100
0.120
0.140
0.160
1R 0.1 0.5 1.0 2.0 3.0
Fri
cti
on
co
eff
icie
nt
ND concentration (wt.%)
Allegro
Friction coefficient averages
Research data indicates 0.5 - 1.0%
fuel consumption saving when
applied to automotive pistons
compared to standard PTFE
Thermoplastics
Nanodiamond powders added to existing polymers & composites
Thermal conductivity without compromise to other properties
Electronics & LED – Thermoplastic
Heat sinks: Thermal & dielectric
properties
Thermoplastic Development:
Thermal conductivity increased 25
- 100% with 0.1wt% NanoDiamond
Low Carbon Vehicles:
Additional structural,
lightweighting &Tg possibilities
PA-66 Thermal Compound, 45 wt.% Overall Loading
References:
• neat PA-66
• compound with 45 wt.% BN loading
Processing:• Carbodeon proprietary
Performance (W/m . K):
• 0.05 wt.%
• 36.3% improvement within in-
plane thermal conductivity
• 29.4% improvement within
average thermal conductivity
• 0.1 wt.%
• 51.4% improvement within in-
plane thermal conductivity
• 38.2% improvement within
average thermal conductivity0
1
2
3
4
5
6
PA-66 Ref45 0.05+44.95 0.1+44.9
in-plane (x/y)
average (x/y/z)
PA-66 Electrically Conducting Thermal Compound, 50 wt.% Overall Loading
References:
• neat PA-66
• compound with 50 wt.% graphite loading
• Graphite filler material, TIMCAL TIMREX®
KS5-75TT Primary Synthetic Graphite
Performance:
• 0.5 wt.%
• 46.3% improvement within in-plane
thermal conductivity
• 40.7% improvement within average
thermal conductivity
Works with a variety of fillers.0
2
4
6
8
10
12
PA-66 Ref50 0.5+49.5
in-plane (x/y)
average (x/y/z)
PA-66 Electrically Conducting Thermal Compound, 50 wt.% Overall Loading
References:
• neat PA-66
• compound with 50 wt.% graphite loading
• Graphite filler material, TIMCAL TIMREX®
KS5-75TT Primary Synthetic Graphite
Performance:
• 0.5 wt.%
• 46.3% improvement within in-plane
thermal conductivity
• 40.7% improvement within average
thermal conductivity
Works with a variety of fillers.0
2
4
6
8
10
12
PA-66 Ref50 0.5+49.5
in-plane (x/y)
average (x/y/z)
In “next steps”, some research has been
done on mechanical properties.
Combination with other mechanical fillers
(micron or nano scale) can be expected to
yield results also.
Thermosets
Nanodiamond powders added to existing polymers & composites
Wide range of thermal and mechanical properties to modify
Electronics & LED – Silicone and
epoxy thermal interface
materials
Abrasion resistance of resins
including resins used in
composites
Various thermal , mechanical and
failure properties in composites.
Project Approach
Property
Requirements,
Test Methods,
Economics
Material and
Process
Understanding
NanoDiamond
Material Selection
(functionalisation)
Dispersion
Methods &
Process
Optimisation
Communication
Conclusions Extremely small amounts of nanodiamond additives can modify a variety of thermal
and mechanical properties in various parent materials – “Hard as Hell, but Cooler”
Success factors
• Dispersion / agglomeration control : surface area is an essential property
• Surface functionalization has to be appropriate
• Combination with other micron or nano scale materials. “Hierarchy”
• Project based approaches
Actions:
• Consider the possibilities of nanodiamond materials within your material development/
product development activities now and in the future
• Form good networks between nanomaterial, polymer, coating, composite, component,
system and OEM parties
• Out of the box thinking, focusing on high value solutions
Carbodeon patents covering aspects of the material - its preparation and properties,
and many of the applications
Carbodeon Ltd. Oy
Pakkalankuja 5
01510 Vantaa
Finland
www.carbodeon.com
www.ndplating.com
Gavin Farmer
Business Development
Mobile: +44 7768 587105
Vesa Myllymäki
Chief Technical Officer
Mobile: +358 50 567 8828