RESEARCH NEWS
Heat-resistant ink for marking metal
Fraunhofer researchers in Germany have developed an extremely heat-resistant ceramic-based ink .
“ For the first time , this enables metal components processed in the automotive industry at temperatures over 1,000 º C to be marked with a code . The code can be scanned and is linked to a database in which all the manufacturing parameters for the component in question are stored . The advantages of the technology are not simply the ability to detect production glitches and defective components at an early stage . It also opens wide-ranging possibilities for designing process chains in the industry more efficiently and reducing their carbon footprint significantly . Even component forgeries can be prevented by means of special additives in the ink ,” explained Fraunhofer .
Overcoming the heat challenge
Marking components so that each one can be tracked and traced is an important requirement for the digitalisation of processes in the manufacturing industry . In metalworking industries , efforts in this area have previously failed because many metal components must be heated in individual process steps . Codes imprinted conventionally are destroyed when heated and can therefore no longer be read .
Prof . Thomas Härtling , group manager for Optical Test Methods and Nanosensors , and his team at the Fraunhofer Institute for Ceramic Technologies and Systems IKTS have now developed an ink that can withstand temperatures of over 1,000 º C in the oven without being damaged . The Ceracode © ink consists of heat-resistant ceramic particles and a glass component . In the oven , the melting glass ensures that the marking is fixed to the metal and yet is still easy to read . The combination of Ceracode © ink and the standardised data matrix code that is in widespread use in the industry is providing new momentum for the digitalisation of production processes in metalworking industries .
Efficiency and sustainability
“ The quality of every component or workpiece can be recorded along the value chain at any time , and defects can
Printed data matrix code on a metal component .
be identified right at the start of production and rectified in a targeted manner . This doesn ’ t just save companies energy — it also means they aren ’ t wasting raw materials and are able to reduce their carbon emissions ,” explained Härtling .
Overall , this makes the production process significantly more efficient and cost-effective . The process data stored in the database also makes it easier to set up adaptive process chains . If a manufacturer knows which physical parameters were used to produce a product , the subsequent steps and processes can be adapted and optimised in a flexible manner .
Depending upon the application scenario , the database can be filled with additional information as required . For example , data on power consumption and power source could be incorporated for each processing step and
Industrial printer and read-out unit in production environment .
Data matrix code on hot-formed sheet metal , printed by an industrial printer .
then used to calculate the greenhouse gas emissions for each component .
“ There are more and more manufacturers who are requesting features like these to enable them to run transparent and resource-efficient production processes ,” explained Härtling .
Customised options
The ink technology can be extensively adapted to customer needs and application . One example is the protection of products against forgeries .
“ To do this , we add special pigments to the formula of the ceramic-based inks so that they are illuminated in a defined colour under UV light . This is an interesting option for industrial customers who purchase parts consisting of particularly expensive metal alloys or components for safety-related systems ,” explained Fraunhofer researcher , Härtling .
As a next step , the Fraunhofer researchers are working on how to imprint curved or shaped metal components . Further developed image recognition algorithms will then be able to read out codes precisely , even on irregular or curved metal surfaces .
While the Fraunhofer IKTS team developed the ink and continues to work on optimising it further , project partner Senodis Technologies GmbH from Dresden is responsible for programming the software and commercialisation . Senodis Technologies is a spin-off of Fraunhofer IKTS ; it primarily targets customers from the metal , automotive and ceramics sectors . n
www . ikts . fraunhofer . de / en
All image : Senodis Technologies GmbH .
18 | ismr . net | ISMR November 2023