Materials research has always played a key role in the development of mankind. It has contributed to the development of new materials with better properties such as strength, durability or greater manufacturing efficiency, and has enabled the creation of lighter structures. Materials testing is essential to ensure reliability and safety, especially in critical sectors such as transport, energy or construction. Testing in the automotive industry, for example, is important to ensure that materials do not fail at key moments.

We often encounter the price-performance dilemma with cheaper, lower quality materials. Purchasing departments often choose cheaper materials, e.g. from China, which can lead to losses and damage to the company's reputation if quality criteria are not met. COMTES FHT a.s. has four departments dedicated to materials research and testing. It has an accredited laboratory for mechanical testing and material analysis. The equipment allows working with small samples, for example from the energy sector, and examining them with light and electron microscopes. This enables them to determine whether the technological conditions of production have been observed and whether the materials meet the customer's requirements.

A sample case of non-compliance with the technological procedure was a segment with a draw bar where the blade was breaking. Analysis by metallographic methods revealed the presence of chromium and molybdenum-based particles, indicating problems in the forming of the material. If such defects are not corrected, fatal tool failure can occur and consequently endanger the operator.

Another challenge is additive manufacturing (3D printing), which can be described as an industrial revolution. It enables the creation of complex geometries and the optimisation of part topologies, saving material and reducing waste. 3D printing is particularly advantageous for rapid prototyping and for smaller series. It also makes it possible to combine different materials, which is not possible with conventional methods. An example is the combination of corrosion-resistant stainless steel and high-strength steel.

In cooperation with a forge in Hradec Králové, they applied a functional layer of nickel alloy reinforced with tungsten carbide to a rolling ring used for untying bearing rings. This layer slows down the degradation of the material and significantly extends the life of the tool. A conventional rolling ring is discarded after three resharpenings, whereas a ring with a functional layer can be used much longer because only a fraction of the material is removed.

The AM SURF project, in cooperation with the MECHATRONIKA Cluster, Amberg-Weiden University of Technology and the Technology Campus in Pilsen, focuses on the optimization of metal component surfaces after 3D printing. Laser polishing improves surface quality and increases the fatigue life of materials. By varying the process parameters during printing, the lowest possible roughness can be achieved, which is crucial for parts that cannot be easily machined. The main objective of the project is to organise expert forums and workshops that strengthen research capacities in the Czech-Bavarian region.

An example is the analysis of the effect of laser polishing on the fatigue life of a material, where a machined and unmachined surface was compared. The results showed a significant improvement in material properties due to this method.

Martina Koukolikova, COMTES FHT a.s., a member of the Klastr MECHATRONIKA