The MA.D.AM project addresses the strong need of wire-based additive manufacturing (AM) for customized value-added metallic materials that are not established yet. The project aims at establishing novel scientific knowledge for the fabrication of novel wire materials and AM parts with hitherto not reached properties, based on the application of high-strength Al-Cu-Li alloys, as cutting-edge candidates for AM in aerospace applications. For this purpose, innovative solid-state materials development and AM processes are utilized to obtain alloys beyond the known thermodynamic borders. The solid-state Friction Extrusion process allows generating phases under non-equilibrium conditions, leading to so far unexplored microstructural states, enabling to produce novel high-performance wire material with tailored properties. To avoid microstructural deterioration and preserve or even improve the beneficial properties of the designed wires, the Solid State Layer Deposition process is employed. The overarching objective of MA.D.AM is to establish the real-world process chain paired with numerical approaches, leading to a digital twin to achieve a hitherto unavailable decryption of the composition-process-microstructure-property relationships for solid-state materials development and AM. To achieve this objective, a systematic multidisciplinary approach based on the combination of sophisticated physical modelling concepts, advanced experimental approaches including characterization techniques and machine learning is pursued. The selected modelling approaches along computational thermodynamics, microstructure and process modelling, together with special-designed (in situ) experiments will establish a clear link between process characteristics and evolution mechanisms such as phase formation and recrystallization kinetics. The digital twin will be built via a novel hybrid modelling strategy based on experimental and numerical data developed on the concepts of machine learning.

The MAGPLANT project is intended to provide a major breakthrough towards the fabrication and application of bioresorbable Mg-alloy implants, which have the remarkable potential of accelerating bone healing while transferring the body’s mechanical load from the implant to the regenerating bone, as the Mg-alloy progressively degrades, thereby avoiding multiple surgical interventions. Moreover Mg is highly biocompatible as it is abundantly present in bone tissue and exhibits mechanical properties similar to those of bone. Although there is currently much research on biodegradable Mg implants, the fundamental aspect for achieving success is controlling the corrosion rate of Mg-alloys in biological media. Because the main form of corrosion on Mg is localized corrosion, a thorough study consisting of localized electrochemical measurements must be performed. In the literature the biodegradable Mg is persistently being addressed as suffering from homogeneous corrosion, which is incorrect and does not provide the information on the microscopic processes occurring as the alloy degrades in contact with biofluids and cellular structures. In the scope of MAGPLANT the corrosion of Mg-alloys will be investigated by using modern localized electrochemical techniques. Therefore the underlying Mg-alloy corrosion mechanisms will be understood from the macro to the microscale level, considering the biological environments of interest. This project fits well into the key societal challenges for H2020 and will contribute to improve Europe’s research position on bioresorbable implants. Such perspective is well supported by the excellence and strong dedication of the host institution in the target research field, along with the research experience of the candidate.

The world is moving towards sustainable economic growth and green technologies; therefore, the high specific strength, easy recyclability and lightweight of Magnesium (Mg) based materials make them potential options to minimize weight, save energy and reduce environmental issues. However, their poor corrosion resistance in aqueous and atmospheric conditions limits their widespread usage in many industrial applications. Enormous effort has been made to protect Mg and its alloys against degradation and improve their service time. Despite that, the questions related to their durability, longevity, biocompatibility, cost and environmental impacts must be resolved. This scientific work aims to develop durable, multifunctional multilayer composite (MMC) coatings to provide long-term corrosion protection to Mg-based materials. Durability and long-term protection will be achieved by using eco-friendly materials and considering interfacial adhesion strength between substrate/composite within the multilayers and their surrounding environments. MMC coatings will be prepared to protect Mg-based materials against corrosion and give a visual response when the coating is damaged to achieve this scientific goal. MMC coating will consist of a self-assembled organic layer, a polymeric composite containing corrosion inhibitor and sensing agents loaded metal-organic frameworks (MOF) using a stimuli-responsive polymeric gatekeeper in a single layer and a top self-cleaning hydrophobic polymeric layer. They will provide adequate long-term corrosion protection of Mg-based structures by the synergistic effect of self-cleaning, passive barrier layers and on-demand release of active corrosion inhibitors from loaded MOF. Corrosion-sensing agents encapsulated MOF will monitor the onset of corrosion upon physical damage to the coatings for large area systems. MMC coatings will ensure minimum cost and environmental impacts consistent with desired properties and help to substitute PFAS.