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Topic of the Thesis

In this project, you will set up an experimental setup using a compact piezo plasma source and investigate it experimentally. The goal is to coat surfaces at atmospheric pressure without using a complex vacuum system. The energy required to ignite the plasma is supplied by a piezoelectric transformer.

Integration into the Research Project

This thesis is part of an industrial project with a manufacturer of PECVD coating systems. The project investigates the use of a compact piezo plasma source for localized surface coating via plasma-enhanced chemical vapor deposition (PECVD).

Objective

In your bachelor’s thesis, you will select suitable components—most of which are commercially available—assemble the reactor, and commission it. You will then investigate ignition stability in initial experiments. When selecting and assembling the components, you have creative freedom and make independent, technically sound decisions. In the master’s thesis, you will also conduct systematic coating experiments and analyze the deposited layers.

Your Responsibilities

Your Profile

• A degree in engineering or the natural sciences, such as mechanical engineering, chemical engineering, materials science, or physics
• Interest in experimental research and plant engineering, as well as a meticulous and independent work style
• Experience with experimental investigations is a plus. You will learn the fundamentals of plasma technology and coating processes as part of your work.

You can start working on this right away. If you’re interested or would like to learn more about this topic, please feel free to contact me.

The post Experimental Study of a Piezo-Plasma Source for Surface Coating appeared first on IKV-Aachen.

© IKV

Topic of the Thesis

The hydrogen economy places the highest demands on materials and joining technologies: Structures must be extremely dense, lightweight, and yet highly durable. Metal-plastic hybrid joints are used precisely where such high-performance interfaces are required—for example, at connection points in innovative pressure tanks, for sealing and electrical connections in electrolyzers, or in flange systems for plastic-based piping. A direct bond between the materials can only be achieved through a weak micro-form-fit connection. Plasma coating of the metal samples specifically optimizes the adhesion of the laser-welded plastic to the metal plate to achieve a material- and form-fit bond without adhesives. In this project, you’ll dive right into applied research: You’ll fabricate your own plastic samples, join them to coated metal components via laser welding, and then characterize the hybrid composites mechanically and microscopically.

This thesis is related to this research project

This project paper is being written in the Joining Technology research group, which specializes in plastic welding and hybrid composites. In this research group, we focus on various welding processes and, through our research, investigate the creation of optimal joints between plastics as well as between plastics and metals.

Objective

The objective of this thesis is the fabrication and experimental characterization of laser-joined metal-plastic hybrid joints. Through the systematic recording of process parameters and subsequent mechanical testing, the effects of the process on the joint properties at the interface are to be understood and documented in a manner that ensures quality.

Your Tasks

Your Profile

• General Mechanical Engineering Program
• Basic understanding of plastics processing and joining processes
• Ability to work independently and in a structured manner
• Some prior laboratory experience is desirable

These are your benefits

• Work in a young, motivated team
• Independent work with close supervision
• Opportunity to contribute to current research projects
• Experimental work on industrial equipment
• Prompt processing, direct contact for questions during the process
• A varied mix of experimental work and data analysis
• Can start immediately

If you’re interested in this assignment, please feel free to contact me. We’ll work out the exact scope and timeline together on a case-by-case basis.

The post The Future of H₂: Manufacturing and Testing of Innovative Plasma-Coated Metal-Plastic Hybrid Composites appeared first on IKV-Aachen.

© IKV

Topic of the Thesis

Conventional contact temperature sensors are relatively slow to respond, which makes it difficult to monitor the process. Furthermore, they provide only a single-point measurement. Coated mold surfaces in the form of thin-film sensors offer decisive advantages in this regard: They allow for the dense placement of individual measurement points at a distance of only about 500 nm from the melt. This provides new insights into the thermal behavior of injection molding with extremely high spatial and temporal resolution. Thus, thin-film sensors could make a decisive contribution to advanced temperature analysis. The only remaining question is whether the coating affects part quality or whether processability is actually improved by better flow properties at the mold surface.

This work is related to this research project

This work is being conducted as part of the “SITO” project, which aims to conduct a detailed investigation and modeling of weld seam formation while taking prevailing process conditions into account. To this end, a thin-film temperature sensor system is being developed in collaboration with Leibniz University in Hanover.

Objective

The goal of your work is to use existing thin-film sensors in injection molding and to examine the dimensional accuracy of the components produced using this method. Any shrinkage effects will be attributed to the residual stresses that develop within the component.

• A degree in engineering or the natural sciences (Mechanical Engineering, Industrial Engineering (Mechanical Engineering or Materials and Process Engineering), Materials Science, Automation Engineering, or Computational Engineering Science (CES))
• Practical experience in plastics processing and measurement and sensor technology is helpful for getting started, but is not a requirement
• You should have a passion for plastics engineering. Depending on your area of study and interests, your work can be focused on design, simulation, or material characterization

These are your benefits

• Independent work with intensive guidance
• Active participation in current research projects
• Individual coordination of tasks and timelines
• Work can begin immediately
• Experimental work on industrial equipment
• Quick turnaround, direct contact for questions during the project
• A varied mix of research, experimental work, and analysis

If you’re interested in writing a thesis at the IKV and in this topic, please feel free to contact me. We’ll work out the exact scope and timeline together on an individual basis.

The post Analysis of the Influence of Coated Mold Surfaces on Part Quality in Injection Molding appeared first on IKV-Aachen.

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Topic of the work

The dispersive mixing effect of mixing elements is particularly important for the breakdown of agglomerates or a second material phase, and thus significantly influences the homogeneity of the extruded melt. To analyze the exact factors influencing the dispersive mixing effect, experiments are being conducted using PP in a mixing section available at the IKV—a section consisting of several blister rings mounted on a 60-mm single-screw extruder and designed primarily for dispersive mixing. A second melt stream is introduced laterally into the mixing section: polystyrene (PS), which is incompatible with PP, or PP with a carbon black masterbatch. By varying the throughput, melt temperature, and the order of the blister rings, the secondary material is fragmented to varying degrees. Before and after each blister ring, side streams are sampled via radial capillaries. The extrudates are examined microscopically, with the size and size distribution of the PS and carbon black particles serving as indicators of the degree of dispersion. The evaluation is performed, for example, using grayscale analysis.

This work is related to this research project

The research project aims to robustly and automatically optimize blend components for single-screw extruders. This thesis is part of a work package in which a objective function for the degree of dispersion is being developed; this function will serve as the basis for automatic simulation-based optimization in subsequent work packages.

Objective

The objective of this thesis is to experimentally characterize the dispersive mixing effect as a function of process and geometric parameters. By taking samples along the mixing section, the development of the mixing effect across the individual blister rings will also be investigated.

Your Task

Your profile

• A degree in engineering or the natural sciences (e.g., mechanical engineering, industrial engineering with a specialization in mechanical engineering or materials and process engineering, automation engineering, computational engineering, or simulation sciences)
• Ability to work independently, conscientiously, and as part of a team
• Interest in experimental work
• Affinity for technology, creativity, and a willingness to learn
• Some experience with extrusion, design, microscopy, or statistical experimental design is desirable but not required

Here are your benefits

• Work in a young, motivated team
• Independent work with intensive support
• Co-design of current research projects
• Individual coordination of tasks and time frame
• Fast processing, direct contact for questions during processing
• Immediate start possible

If you are interested in writing a thesis at the IKV and in this research topic, please feel free to contact me. We will work out the exact scope of the thesis and the timeline on a case-by-case basis. There is also the option of working on a customized research topic using the OpenFOAM simulation software.

The post Mix it! – Dispersive Mixing in the Extruder appeared first on IKV-Aachen.

© IKV

Thematic Classification of your Thesis

The Packaging and Packaging Waste Regulation (PPWR) will require packaging manufacturers to use a certain proportion of recycled materials in their packaging products from 2030 onwards. Owing to local material variations in the extrudate, however, it poses a considerable challenge to extrude films with a uniform coating thickness across their entire width. This can lead to insufficient barrier properties in certain areas, which can be specifically improved through the application of plasma barriers.

For the applied plasma barriers to function reliably in industrial use, their quality must nevertheless be continuously ensured. Since the coating is carried out on moving film material during the ongoing process, fast and non-destructive testing methods are required for this purpose. These should enable seamless monitoring of the coating properties, such as the barrier effect and coating homogeneity, already during production.

Background of your Thesis

The IGF project ‘HSI – Investigation of Hyperspectral Imaging as a Potential Quality Assurance Technology for Plasma-Functionalised Packaging’ is concerned with the testing of a novel measurement method for the process monitoring of coated films.

Scope of your Thesis

Within the scope of this work, film samples are produced by means of Plasma Enhanced Chemical Vapour Deposition (PECVD) and characterised with regard to their barrier function. Polypropylene (PP) and polyethylene (PE) films serve as substrates. These are first coated and subsequently examined using various analytical methods.

On the basis of the data thus obtained, a regression model is developed that relates the acquired spectral data to the process parameters as well as to the oxygen transmission rate (OTR) values. Depending on the scope of the work, the analyses are extended to include hyperspectral imaging (HSI). By comparing the hyperspectral data with the spectral data collected beforehand, a statement is to be made regarding the achievable measurement accuracy.

I will, of course, assist you in familiarising yourself with the broad field of plasma coatings and take your creative ideas into consideration. Close supervision is essential, particularly for thesis projects, and will serve as the foundation for your successful completion.

The specific content and timeline of your thesis will be determined in consultation with you, taking your prior knowledge into account. In addition, there is the possibility of addressing the topic in a modified form within the framework of a research laboratory or a project-based module.

Your Profile

• A degree in engineering or the natural sciences (General Mechanical Engineering, Industrial Engineering (Mechanical Engineering or Materials and Process Engineering), Materials Science, Environmental Engineering, Applied Chemistry, or Applied Polymer Science)
• Willingness to learn and engage with new challenges related to plasma technology
• An independent and structured approach to working
• Previous experience in a laboratory setting is desirable, but not required

AG Plasma offers you a dynamic, young team in which you and your skills can grow during the course of your thesis, with clear objectives and diverse tasks. If you are interested in contributing to the field of plastics processing with your creative ideas, please feel free to get in touch with me!

The post Process monitoring of plasma-functionalised media appeared first on IKV-Aachen.

© IKV

The work is being conducted in this working group

The Plasma and Surface Technology Working Group develops, optimizes, and characterizes plasma-assisted coating processes as well as functional surfaces and thin films.

Objective

The goal is to investigate changes in ignition duration, the spectra recorded via optical emission spectroscopy (OES), and the thickness, composition, and homogeneity of the substrate layers. You will correlate these results with the coating condition of the ignition wires and evaluate possible relationships between plasma behavior and layer formation.

Your Assignment

Your Profile

• A degree in a natural science or technical field, such as physics, materials science, or mechanical engineering
• Ability to independently and meticulously address experimental problems
• Knowledge of plasma or coating technology is helpful but not required
• Interest in hands-on experiments and experimental plant engineering

The post Parasitically Coated Ignition Wires: Effect on Plasma and Substrate Layer appeared first on IKV-Aachen.

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Topic of the Thesis

Plastic packaging is largely made from polyolefins. These account for nearly two-thirds of all post-consumer plastic waste. The most common types of polyolefins are polyethylene (PE) and polypropylene (PP). Current sorting technologies cannot guarantee complete separation of PP and PE, so cross-contamination must be expected. In Germany, a distinction is currently made between a flexible PE-LD fraction and the
dimensionally stable PE-HD fractions, PP fractions, and various blended polyolefin fractions. Quality assurance for processed plastic waste—known as recyclates—is necessary, among other reasons, because contamination of PE with PP (or vice versa) affects plastic processing methods (e.g., film extrusion) and impairs the performance of the final product. Knowledge of the composition is therefore crucial for ensuring the quality of the recyclate. One method for assessing recyclate quality is the relative comparison of melt enthalpies using DSC.

The paper is being written in this working group

The tests conducted in the physical laboratory of the Center for Plastics Analysis and Testing (KAP) provide significant support to both industry and the institute’s own research in validating manufacturing parameters. Another focus is on material characterization through thermal, spectroscopic, rheological, and chromatographic analyses to evaluate material behavior and thus address not only research questions but also industrial challenges. Through these analyses, the laboratory provides essential insights for optimizing production processes and improving component quality. This also includes the analysis of recycled materials and gaining a deeper understanding of their composition.

Objective

The goal of this thesis (bachelor’s or master’s thesis) is to adapt the evaluation routine developed for determining PE/PP fractions in defined mixtures to polyolefin recyclates of unknown composition. To this end, an evaluation method will be developed. The thesis begins with a literature review on potential challenges in the thermal analysis of unknown polymer blends and current approaches to characterizing PE/PP fractions. The focus of the thesis is on the analysis of recycled materials (e.g., differences in crystallization, additives). Recyclates of unknown composition and virgin material blends of known composition, as well as corresponding DSC measurement results, are available for the development of the evaluation routine (e.g., calibration curves). In addition, specific further blends and recycled materials are to be examined in order to validate the developed evaluation routine. For this bachelor’s thesis, the initial focus is on characterizing the virgin material blends and developing an automated evaluation method for determining the respective polymer fractions in each blend system. As part of a master’s thesis, recycled materials of unknown concentration will also be evaluated for their foreign polymer content based on calibration systems to be developed within this thesis. Furthermore, the automated analysis must be validated with regard to the possible presence of other foreign polymers (e.g., PET, PS, etc.) and optimized as needed.

Your Assignment

• Literature Review and Methodology Development
• Sample Preparation
• Training in the operation of a DSC and the interpretation of results
• Evaluation and classification of the generated results

Your Profile

• A degree in engineering or the natural sciences (e.g., mechanical engineering, industrial engineering, materials science…)
• Interest in analytical tasks and hands-on work in the lab
• An independent, structured, and team-oriented approach to work

Here are your benefits

• Work in a motivated team
• Independent work with support tailored to your needs
• Working on research-related questions
• Individual coordination of tasks and timelines
• Experimental work with laboratory equipment
• Short-notice start possible / quick turnaround without delays

If you’re interested in this assignment, please feel free to contact us. We’ll work with you individually to determine the exact scope and timeline.

The post Development and Validation of a DSC Analysis Routine for Determining the PE/PP Content in Polyolefin Recyclates appeared first on IKV-Aachen.

© IKV

Thematic classification of your thesis:

The application of functionalised coatings through plasma processes allows for the targeted modification of the surface properties of plastics. Consequently, characteristics such as gas permeability, scratch resistance, wettability, and resistance to various substances can be precisely controlled. Consequently, the utilisation of plasma technology offers novel perspectives in a variety of disciplines, including but not limited to automotive, packaging, medical, and electrical engineering. This technology is of significant value in the pursuit of a more sustainable future.

In order to facilitate continuous development and optimisation of plasma coatings, it is essential to acquire a comprehensive understanding of the material transport processes that occur through ultrathin plasma layers. In this context, simulation is a powerful tool, serving not only to advance understanding of these processes but also to provide the potential to transfer this knowledge to other products.

Background of the thesis:

The DFG project “PermaSim – Development of a Semi-Empirical Model for the Description of Temperature-Dependent Permeation Mechanisms through Plasma-Polymerized Barrier Layers” is dedicated to the development of a simulation model for the analysis of gas permeation through nanoscale layers applied using the Plasma Enhanced Chemical Vapor Deposition (PECVD) process.

Objective:

This thesis aims to further develop an existing quartz crystal microbalance-based measurement system for sorption measurements of ultrathin plasma layers. The goal is to optimise the system’s reliability and establish a method for investigating the sorption behaviour of polymer coatings at different pressures. Depending on the scope of the thesis, the existing simulation model used to describe permeation behaviour in ultrathin plasma layers will also be validated using sorption measurement data.

I will assist you in familiarising yourself with the broad field of plasma coatings and take your creative ideas into consideration. Close supervision is essential, particularly for thesis projects, and will serve as the foundation for your successful completion.

Work Packages:

The specific content and timeline of your thesis will, of course, be determined in consultation with you, taking your prior knowledge into account. In addition, there is the possibility of addressing the topic in a modified form within the framework of a research laboratory or a project-based module.

Your profile:

• A degree in the natural sciences or engineering (e.g., general mechanical engineering, industrial engineering, materials science, environmental engineering, applied chemistry, applied polymer science)
• Willingness to learn and engage with new challenges related to plasma technology
• An independent and structured approach to working
• Initial experience with engineering tasks is desirable, but not essential
• Initial experience with simulation tasks is desirable, but not essential

AG Plasma offers you a dynamic, young team in which you and your skills can grow during the course of your thesis, with clear objectives and diverse tasks. If you are interested in contributing to the field of plastics processing with your creative ideas, please feel free to get in touch with me!

The post Sorption Processes in Ultrathin Polymer Coatings appeared first on IKV-Aachen.

© IKV

Thematic Classification of your Thesis:

The packaging industry faces a significant regulatory and technological challenge: Starting 2030, manufacturers will be required to incorporate a specified minimum proportion of recycled content in packaging. This mandate aims to reduce resource consumption and to strengthen the circular economy within the field of plastic packaging.

In practice, there are currently limitations associated with post-consumer recycled (PCR) materials, particularly regarding the necessary barrier properties. Of primary concern is the reliable retention of potentially migrating substances, which is critical for a wide range of packaging applications.

Against this backdrop, our plasma research group aims to enhance the barrier performance of PCR-based packaging materials through the targeted application of plasma technology. The focus lies on the development of effective migration barriers, enabling the safe use of recycled materials in demanding packaging systems. The objective is to provide industry with a technologically robust and economically viable solution that consistently meets required quality and safety standards.

Despite our extensive expertise in the development of barrier coatings, there remains substantial potential for technological advancement. The process gas required for the PECVD process is introduced into the substrate to be coated via gas lances. In order to ensure a homogeneous gas distribution, which is essential for the uniform formation of the barrier layer, a fluid-dynamic optimisation of the gas lances is required.This approach enables a significant enhancement of the barrier layer performance.

Scope of your Thesis:

In this thesis, a simulation model will be developed to describe the gas distribution in hollow-body samples coated in our plasma reactor using PECVD. The objective is to model and evaluate the flow and distribution characteristics of the process gases in order to ensure the most homogeneous possible gas distribution within the hollow bodies. To this end, various geometries will be investigated, with particular emphasis on systematically varying the gas inlet configuration to achieve a uniform and efficient flow throughout the interior of the hollow bodies.

For the stepwise development and improved understanding of the model, simplified cylindrical geometries will initially be simulated. Building on these results, the approach will then be extended to more complex hollow body structures.

Finally, the developed model will be experimentally validated using one of our reactors, allowing the simulation results to be compared with real process conditions and their predictive accuracy to be assessed. Depending on the scope of the project, the methodology may further be applied to additional complex geometries, which will also be experimentally validated.

I will assist you in familiarising yourself with the broad field of plasma coatings and take your creative ideas into consideration. Close supervision is essential, particularly for thesis projects, and will serve as the foundation for your successful completion.

Work Packages:

The specific content and timeline of your thesis will, of course, be determined in consultation with you, taking your prior knowledge into account.

Your Profile:

• Technical or scientific degree (e.g. mechanical engineering, industrial engineering, materials science, environmental engineering…)
• Willingness to learn and familiarize yourself with new problems relating to plasma technology
• Independent and structured way of working
• Initial experience in a laboratory environment is desirable, but not necessary
• · Initial experience with simulation work is desirable, but not essential

AG Plasma offers you a dynamic, young team in which you and your skills can grow during the course of your thesis, with clear objectives and diverse tasks. If you are interested in contributing to the field of plastics processing with your creative ideas, please feel free to get in touch with me!

The post Simulation-based barrier optimisation for PCR packaging appeared first on IKV-Aachen.

© IKV

Topic of the work:

Haptically appealing soft-touch surfaces determine the perception of quality, particularly in car interiors. However, conventional soft-touch components are made of non-recyclable material composites, such as PVC, PUR and PP. With the Foam2Cycle project, IKV presented an alternative for the production of sustainable soft-touch composites based on foamed thermoplastic elastomers (TPE) at the K trade fair. The combination of a TPE processed by thermoplastic foam injection molding (TSG) with a polypropylene (PP) enables mechanical recycling without material separation of the composite components and the return of old components to the composite.

The work is written in this working group:

In the thermoplastic foam injection molding working group, we deal with various aspects of the innovative lightweight construction technology of foam injection molding. The main areas of research include design guidelines for lightweight structural construction, process optimization for foamed moulded parts to be welded and the improvement of surface qualities for use in automobiles or white goods.

Objective:

The aim of your work is to evaluate the recycling potential of the soft-touch composite. In particular, the feasible recyclate usage rates and their influence on the mechanical properties and the manufacturing process are to be analyzed. Another important aspect is the investigation of the influence of foaming agent residues from the foaming process on recyclability.

Your tasks:

Your profile:

• Technical or scientific studies (general mechanical engineering, industrial engineering, materials science, environmental engineering, applied polymer science…)
• Enthusiasm for practical work on the machine
• Communicative and a team player
• Motivation and commitment

These are your benefits:

• Co-design of current research projects
• Individual coordination of tasks and time frame
• Experimental work on modern industrial plants
• Fast processing, direct contact for questions during processing
• Varied mix of research, experimental work and analytics
• Immediate start possible

If you are interested in writing your thesis at IKV and in this task, please get in touch with me. We agree on the exact scope of content and schedule individually. I and my assistants look forward to welcoming you to our working group and to shaping the future of foam injection molding together with you

The post Evaluation of the recyclability of 2K soft-touch components with foamed TPE appeared first on IKV-Aachen.