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Micro-forming - Investigation of nanoscale material behavior during the forming of metallic materials using embossing and furrow kinematics to generate optically functional microstructures

The goal of the research project is the generation of large-area micro-optical elements with high structure density and minimal defect ratio for visible applications by forming the near-surface area of metallic layers. The working hypothesis is that it is possible to produce diffractive and refractive microstructures for optical applications reliably by forming processes with suitable process parameters, strategies and tools. The aim of the project is to fundamentally investigate the forming mechanisms during embossing and ruling processes and to determine suitable parameters and strategies for reproducible production. Profile quality and roughness must be subject to narrow limits in order to enable applications for wavelengths in or below the visible range.The project aims the fundamental analyzation of flow properties while forming different materials to generate refractive and diffractive microstructures. Based on this, optimized tools will be developed and processes for the generation of structured surfaces with high structure density will be investigated. Therefore, optimized machining parameters for manufacturing processes of micro-optical arrays and gratings will be determined. The machining is carried out in different materials. In contrast to other RSA alloys, the higher-strength amorphous Al alloy RSA 501 did not show any damages caused by particle inclusions in machining experiments and will be investigated with regard to its suitability for micro-forming processes. Based on classical ruling processes of diffraction gratings, thin Au layers (< 1 µm) are to analyze. These provide an excellent basis for subsequent galvanic depositions. In addition, amorphous, chemically deposited nickel-phosphorus layers are investigated. These can be used in the production of e.g. injection moulding tools due to their high strength and hardness.

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Daniel Rolón, M.Sc.
+49 30 314-23553
Room 102