CREATe-Net is composed of 3 academic institutions in Europe (Saarland Univ., DE; Technical Univ. of Catalonia, ES; and INM - Leibniz Institute for New Materials, DE), 3 non-academic institutions in Europe (AB Sandvik Coromant, SE; Steinbeis Research and Innovation Centers, DE; and Nanoforce Ltd., UK), as well as 6 academic partners outside Europe (CSIR - Council for Scientific and Industrial Research, ZA; Univ. Católica de Uruguay, UY; Instituto de Investigaciones en Ciencia e Ingeniería de Materiales, AR; Univ. de Concepción, CL; Univ. de Sao Paulo, BR; and Georgia Institute of Technology, US). The network will cooperate in the field of design, processing and characterization of novel composite materials for resource-efficient applications and environmentally friendly technologies, in particular energy storage, bearings, electrical contacts, and cutting tools. The purpose of the network is to combine different thematic expertises of the academic and industrial network members in the multidisciplinary field of materials science and engineering in order to design new composite materials with superior properties and performance. The expertise of the network includes: a) design by modelling at different scales (e. g. atomistic modelling, thermodynamic and kinetic modelling, finite element modelling); b) novel processing methods (e . g. atomic layer deposition, severe plastic deformation and rapid solidification); c) advanced characterization methods (e. g. serial sectioning and atom probe tomography, high resolution transmission electron microscopy); d) processing/characterization of carbon materials, metal and ceramic matrix composites as well as functionally graded materials; and e) performance testing for targeted applications (available through special designed testing facilities at the research centres and industrial partners). Two workshops and one final conference will contribute to the exchange of knowledge beside the exchange of researchers.

Miniaturization, advanced high performance materials and functional surface structures are all drivers behind key enabling technologies in high added value production. It is in such areas that ultrashort pulse lasers have enabled completely new machining concepts, where the big advantages of laser machining are combined with a quasi non-thermal and therefore mild process, which can be used to machine any material with high precision. An important obstacle however that hinders the full exploitation of the unique process characteristics, is the lack of a smart / adaptive machining technology. The laser process in principle is very accurate, but small deviations, e.g. in the materials to be processed, can compromise the accuracy to a very large extend. Therefore feedback systems are needed to keep the process accurate. Within this project the goal is to develop an adaptive laser micromachining system, based on ultrashort pulsed laser ablation and a novel depth measurement sensor, together with advanced data analysis software and automated system calibration routines. The sensor can be used inline with the laser ablation process, enabling adaptive processes by fast and accurate 3D surface measurements. The integrated sensor can be used to: • measure the surface topography while machining a part, in order to adapt the micromachining process, leading to highly increased machining accuracies and no defects, • measure the surface topography before machining, to scan for existing surface defects that can be removed in an automatically generated machining process, • measure complex shaped objects prior to machining, to precisely align the machining pattern to the workpiece, • quickly validate results after machining. Therefore, the main objective of this project is to develop a sensor based adaptive micro machining system using ultra short pulsed lasers for zero failure manufacturing.

SHARK will unlock the potential for laser texturing for the generation of functional surfaces by boosting the productivity, efficiency and flexibility of the process. This will provide the European industry with a highly robust, cost effective and environmentally friendly system that is capable of producing a broad range of functional surfaces at industrial scale throughputs, and place Europe in an unassailable lead in this key area of manufacturing. SHARK will advance laser surface texturing from the current ‘trial and error’, lab-scale concept into a highly predictable, data driven industrial approach by developing a digitally enabled knowledge management platform with a comprehensive database of process parameters and functionalities. SHARK system will be configured as an Open-platform independent of the laser source manufacturers, which for long, has been one of the main limitations for the process. SHARK’s system will be underpinned by a number of technology advances. Two laser surface texturing technologies will be developed, both based upon nanosecond fibre lasers. Pseudo Random laser texturing and Direct Laser Interference Patterning will be employed, offering complementary techniques to yield a highly flexible tool capable of delivering wide range of functional surfaces with exceptional productivity and excellent process efficiency. The project will develop surface texture predictive modelling to rapidly define key process variables required for specific surface functionalities. This will be combined with inline surface characterisation to enable rapid feedback and inbuilt quality assurance. The project will deliver the following benefits: • The capability to deliver surface functionalities into real products for less than 10% of the cost of the conventional part • Greater than 20% improvement in product performance based on the surface functionalities deployed. • Accelerated product development • Strengthened global position of European manufacturing