Materials for Industry 4.0

Introduction :

The term "Industry 4.0" refers to a new phase of the Industrial Revolution that emphasizes connectivity, automation, machine learning, and real-time data. Industry 4.0, which includes IIoT and smart manufacturing, brings together physical production and operations with intelligent digital technology, machine learning, and big data to create a more complete and better connected ecosystem for businesses that focus on manufacturing and supply chain management. Even while every business and organization today is different, the need for connection and access to real-time information across processes, partners, products, and people is a problem that they must all face.

Materials in Industry :

• First Industrial Revolution (late 18th to mid-19th century): The use of machines to manufacture goods replaced manual production techniques during the First Industrial Revolution. Metals like iron and steel were predominantly employed at this time to build the machinery and infrastructure required to sustain mass manufacturing.

• Second Industrial Revolution (late 19th to early 20th century): New materials like aluminium and plastic were developed during the Second Industrial Revolution, enabling the creation of items that were lighter and more productive. Additionally, as energy usage increased, new electrical materials and components were created.

• Third Industrial Revolution (late 20th century): Electronics and computer technology were widely used during the Third Industrial Revolution, often known as the Digital Revolution. Semiconductors, integrated circuits, and other electronic components were utilized during this time.

• Fourth Industrial Revolution (present day): The Internet of Things (IoT), artificial intelligence (AI), and automation are just a few examples of the cutting-edge technologies that make up the Fourth Industrial Revolution, or Industry 4.0. Carbon fibre reinforced polymers (CFRPs), nanomaterials, 3D printing materials, and smart materials were all employed at this time.

Importance of Materials in Industry 4.0

• Enabling the development of advanced technologies: The fusion of cutting-edge technologies like automation, artificial intelligence, and the Internet of Things (IoT) defines Industry 4.0. Materials with distinctive characteristics are needed to enable these technologies. For instance, the construction of energy-efficient automobiles and airplanes requires the use of lightweight, high-strength materials like carbon fibre reinforced polymers (CFRP)

• Enhancing product performance: The performance of items can be improved by materials having distinctive qualities. For instance, adding nanoparticles to electronic equipment can increase their efficiency and enhance conductivity. Biocompatible materials can increase the effectiveness and safety of implants in the medical field.

• Enabling new and innovative products: The construction of novel and cutting-edge items that were previously considered to be unattainable is now conceivable thanks to the discovery of new materials. For instance, the adoption of 3D printing materials has made it possible to produce complicated parts quickly and precisely. This has created new opportunities in industries including aircraft, transportation, and medical equipment.

• Supporting sustainability: In Industry 4.0, the creation of sustainable materials is taking on more significance. To lessen the negative effects of industrial processes on the environment, products like biodegradable plastics and renewable energy sources are being created. Manufacturers may produce goods that are both high-performing and ecologically sustainable by employing these materials.

Materials used in Industry 4.0

The materials used in Industry 4.0 are different from those used in previous industrial revolutions. They are designed to meet the demands of high-tech applications and have unique properties such as lightweight, high strength, and resistance to wear and tear. Here are some examples of materials that are changing the face of manufacturing in Industry 4.0.

Carbon fibre reinforced polymer :

Carbon fiber-reinforced polymers, carbon-fibre-reinforced plastics, and carbon-fiber reinforced-thermoplastic (CFRP, CRP, CFRTP), also referred to as carbon fibre, carbon composite, or simply carbon, are extremely durable and light fiber-reinforced plastics. CFRPs can be expensive to create, but they are frequently employed in areas where a high strength-to-weight ratio and stiffness are necessary, including sports equipment, aircraft, automotive, civil engineering, and a growing range of consumer and technical applications.

        The lightweight, highly-stable composite materials known as CFRPs are employed in a variety of applications. They are manufactured by mixing a polymer resin with carbon fibres, which results in a substance that is more durable and lightweight than many metals. The production of light, fuel-efficient cars depends heavily on CFRPs, which are also utilized widely in the aerospace, automobile, and sports equipment sectors.

Production methods :

(1) Molding : Carbon fibre cloth sheets can be layered into a mould that has the final shape of the product to create CFRP pieces. To maximize the strength and stiffness attributes of the finished material, the alignment and weave of the cloth fibres are selected. Epoxy is subsequently poured into the mould, which is either heated or air-cured. The final component is rigid, robust for its weight, and extremely corrosion-resistant.

(2) Autoclave technology: A popular technique for producing high-quality Carbon Fibre Reinforced Polymers (CFRPs) is autoclave technology. A pressure vessel in essence, an autoclave enables exact control of temperature, pressure, and cure time during the manufacturing process.A high-quality composite material with consistent qualities can be produced by using autoclave technology, which enables exact control over the curing process.

(3) RTM ( Resin Transfer Molding ) : Resin Transfer Molding (RTM) is a process used for manufacturing composite materials, including Carbon Fiber Reinforced Polymers (CFRPs). In comparison to other production techniques, the RTM process has a number of benefits. The capacity to manufacture huge, complicated items with excellent precision and repeatability is one of the main benefits. 

Nanomaterials :

Nanomaterials are substances that have at least one dimension, usually between 1 and 100 nanometers (nm), in the nanometer range. A wide range of materials, including metals, semiconductors, ceramics, and polymers, can be used to create these materials. Nanomaterials have grown in significance in a number of sectors, including materials science, electronics, medicine, and energy due to their special features.

The high surface area-to-volume ratio of nanomaterials, which has a substantial impact on their chemical, mechanical, and electrical properties, is one of their most important characteristics. Furthermore, the nanoparticles' size and form can be precisely modified, enabling the tailoring of attributes for particular applications.

3D printing materials :

The method of 3D printing, sometimes referred to as additive manufacturing, involves building up successive layers of material until the desired thing is completed. Different kinds of 3D printing processes exist, and they all use various kinds of materials. 

The following are some of the most typical 3D printing materials:

1. Plastics : Thermoplastic, which comes in several varieties including ABS, PLA, PETG, Nylon, and TPU, is the most often used material for 3D printing. These materials provide good strength, flexibility, and durability and are simple to print in. They are frequently employed in the production of prototypes, toys, and consumer goods.
2. Metals: Copper, titanium, stainless steel, and other metals can also be 3D printed. Several processes, including Direct Energy Deposition (DED), Powder Bed Fusion (PBF), and Binder Jetting, are used in metal 3D printing. Components for the aerospace and medical industries are frequently produced using metal 3D printing.
3. Ceramics : Stereolithography (SLA), a method for 3D printing ceramics, uses a photopolymer resin that has been filled with ceramic particles. The sintered ceramic object is produced from the printed parts. Bone replacements and dental implants are frequently produced using ceramic 3D printing.
4. Composites : Composites are substances created by mixing two or more substances to yield a new substance with improved qualities. To manufacture robust, lightweight objects, carbon fibre reinforced polymers (CFRPs) are frequently utilised in 3D printing. The aerospace and automobile industries frequently use these materials.
5. Bioinks : Bioinks are materials that can be 3D printed to create living tissues and organs. These materials are typically made from a mixture of living cells, biocompatible polymers, and growth factors. Bioinks are used in medical research for creating personalized implants and replacement tissues.
6. Food :  Edible things can also be produced using 3D printing technology. Food goods can be 3D printed using substances like chocolate, dough, and sugar.

Smart Materials  :

A class of materials known as "smart materials" is created to react predictably and controllably to changes in their surroundings or external stimuli. In reaction to an external stimuli, these materials have the capacity to alter their characteristics, such as size, shape, stiffness, colour, or electrical conductivity. Intelligent or responsive materials are other names for "smart" materials.

1. Shape memory alloys (SMAs): SMAs have the ability to recover their original shape after being deformed by applying heat or stress. They are commonly used in medical implants, actuators, and sensors.

2. Piezoelectric materials: These materials produce an electrical charge when subjected to mechanical stress or pressure. They are commonly used in sensors, actuators, and energy harvesting devices.

3. Electrochromic materials: These materials change their color or optical properties in response to an electrical stimulus. They are commonly used in smart windows, mirrors, and displays.

4. Thermochromic materials: These materials change their color in response to changes in temperature. They are commonly used in temperature sensors and displays.

5. Shape memory polymers (SMPs): SMPs can change their shape when subjected to a specific temperature or external stimuli. They are commonly used in biomedical devices, drug delivery systems, and self-healing materials.

6. Magnetorheological (MR) materials: MR materials change their viscosity or stiffness when subjected to a magnetic field. They are commonly used in dampers, clutches, and brakes.

Real-time applications :

• Airbus  : Additive manufacturing or 3D printing has revolutionized the way products are being manufactured. It allows for the production of complex geometries and customized products. For example, in the aerospace industry, Airbus is using 3D printing to produce lightweight parts for its A350 XWB aircraft, which has helped reduce fuel consumption.

  

• BMW : Composites are substances created from two or more constituent substances that have various physical or chemical characteristics. They are being employed more frequently in a variety of industries to create products that are both light and durable. For instance, in the automotive sector, BMW produces lightweight i3 electric vehicle components utilising carbon fibre reinforced polymers (CFRP), which has improved the vehicle's performance and range.

Limitations :

While materials play a critical role in supporting Industry 4.0 technologies and processes, there are some limitations and challenges that must be addressed:

1. Cost: Some advanced materials, such as composites and nanomaterials, can be expensive to produce, which can increase the overall cost of manufacturing processes.
2. Processing challenges: Certain materials, such as ceramics and composites, can be difficult to process, requiring specialized equipment and expertise. This can limit their adoption in some industries.
3. Limited availability: Some materials, particularly rare earth metals, may have limited availability or be geographically constrained, which can create supply chain challenges.
4. Environmental concerns: Certain materials, such as plastics and some nanomaterials, may pose environmental risks if not properly managed throughout the manufacturing process and end-of-life disposal.
5. Regulatory hurdles: The use of some materials may be subject to regulations, particularly in industries such as aerospace, automotive, and biomedical, where safety and performance are critical.

Addressing these limitations will require a collaborative effort between material scientists, manufacturers, regulators, and other stakeholders to find solutions that support the development of sustainable and efficient manufacturing processes while mitigating risks and challenges associated with material use.

Conclusion :

Materials are essential for Industry 4.0, providing properties and functionalities to support new technologies and innovative products. However, there are limitations and challenges associated with the use of these materials, such as cost, processing challenges, limited availability, environmental concerns, and regulatory hurdles. To address these limitations, collaboration and innovation across different sectors is needed to find solutions that support efficient, safe, and sustainable manufacturing processes.

References :

• The impact of smart materials, digital twins (DTs) and Internet of things (IoT) in an industry 4.0 integrated automation industry- 
• Ahmad Majid Qazi, 
• Syed Hasan Mahmood, 
• Kanu Gopal
• Defining multivariate raw material specifications in industry 4.0 - 
• Joan Borràs-Ferrís
• Daniel Palací-López
• Alberto Ferrer
•  Implementing Industry 4.0 technologies in self-healing materials and digitally managing the quality of manufacturing -
• Mohd Ammar, 
• Abid Haleem, 
• Ajay Singh Verma
• Improving material quality management and manufacturing organizations system through Industry 4.0 technologies - 
• Mohd Ammar, 
• Abid Haleem, 
• Shashi Bahl
• 3D printing – A review of processes, materials and applications in industry 4.0 -
• Anketa Jandyal, 
• Ikshita Chaturvedi, 
• Mir Irfan Ul Haq
• Data science applications for predictive maintenance and materials science in context to Industry 4.0 -
• Sufiyan Sajid, 
• Abid Haleem, 
• Manoj Mittal
• Automation and manufacturing of smart materials in additive manufacturing technologies using Internet of Things towards the adoption of industry 4.0 - 
• Reem Ashima, 
• Abid Haleem, 
• Someet Singh
• An Industry 4.0 Approach to the 3D Printing of Composite Materials - 
• Bronwyn Fox, 
• Aleksander Subic

Group Members :

SR. NO.	NAME OF THE STUDENT	ROLL NO.	PRN NO.
1	Hudaifa Wasim Madki	57	12010195
2	Niishiraj Nitin Mane	59	12220010
3	Kaustubh Vinod Palande	65	12220132
4	Om Madhukar Panchal	66	12220273