Development of new processes based on a reactor-injector of nanoparticles for plasma deposition of multifunctional and sustainable nanocomposite coatings (RI-plasma)

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The concept of multifunctional coatings has become a prerogative in the development of innovative surfaces. For several internationally competitive applications, one challenge is to obtain nanocomposite (NC) coatings formed by small (<10 nm), isolated (non-aggregated) and well-dispersed nanoparticles (NPs). In this context, we wish to explore in this interdisciplinary research collaboration, the potential of a front-edge, "safe-by-design", versatile, green, and scalable method for deposition of multifunctional and sustainable NC thin films. The targeted method with high potential for industrial applications is based on a reactor-injector of NPs (based on Kemstream's commercial atomizer) coupled to advanced plasma processes. More specifically, this method allows to synthesize NPs from liquid organometallic precursors just before their injection into a deposition reactor. This prevents any agglomeration associated with the vaporization of droplets and further reduces potential human and environmental risks linked to the manipulation of NPs during synthesis and processing. In a first step, organometallic precursors will be identified and developed for the synthesis of metal oxide NPs and the experimental parameters suitable for RI-adapted hydrolysis will be determined. The injection of NPs will then be carried out in two types of non-equilibrium (or non-thermal) plasma reactors of interest to the Canadian company Plasmionique, namely reduced-pressure capacitive RF discharges for batch-like processing and homogeneous dielectric barrier discharges at atmospheric pressure for roll-to-roll continuous treatments. In line with the innovation strategy expressed by our industrial partner Safran and the very high added value of NC coatings in the fields of aeronautics and space exploration (A&S), special attention will be devoted to NC thin films based on NPs of metal oxides (ZnO and NiOx) dispersed in various matrices including "diamond-like carbon". Specifically, we will focus on all the factors driving the evolution of the physical and chemical properties of multifunctional and sustainable NC thin films, and, in particular, their mechanical properties under extreme ageing conditions.