Ceramics from everyday use to high-tech applications

Industrial applications require materials that can reliably withstand stress. High temperatures, abrasive media, and aggressive chemicals are often critical factors. This is where technical ceramics show their strengths: they are wear-resistant, corrosion-resistant, and functional, even where metals reach their limits.

Research at the Fraunhofer Center HTL: The ISC combines its expertise in materials development, process simulation, and component analysis under one roof at its Center for High Temperature Materials and Design (HTL). In addition to monolithic ceramics, the focus is on ceramic matrix composites (CMC) and ceramic-related materials such as metal-ceramic composites and powder metallurgical material systems.

What makes us special: We support application-specific component development along the entire process chain, from design, raw material selection, shaping, and heat treatment to finishing and quality control.

Our focus areas:

• Computer- and database-based development and optimization of oxide and non-oxide ceramics, silicate ceramics, hard metals, and ceramic and metal-ceramic composites 
• Simulation-based component design for complex thermomechanical requirements
• Microstructure analysis and optimization
• Additive manufacturing from prototypes to small series
• Heat process development for energy savings, increased efficiency, and quality improvement 
• Invasive and non-destructive material and component testing under representative operating conditions

Special attention is paid to the supportive use of digital methods: Material and thermodynamic databases as well as microstructure models and FE simulations enable tailor-made solutions for components that must withstand extreme loads and be manufactured in a resource-efficient manner.

Ceramics are considered durable and wear-resistant. These properties in themselves contribute to sustainable use. At Fraunhofer ISC, Center HTL, sustainability is considered even more comprehensively: The focus is on how resources and energy can be saved in a targeted manner along the entire ceramic process chain.

One focus is on optimizing thermal processes. Based on precise measurement methods, such as thermo-optical dilatometry, in combination with FE simulations, thermal processes are designed in such a way that energy consumption can be significantly reduced while at the same time improving quality and reducing waste. In projects such as HTPgeoX, corresponding strategies have been implemented on an industrial scale.

Digital process chains help to further reduce material and energy consumption. These include thermal simulations, process data analysis, and the targeted use of modeling tools. In combination with efficient material selection, resource-saving solutions can be anchored early on in the development process.

The topic of sustainability also becomes concrete at the application level: Center HTL develops ceramic heat exchangers, filters, and storage components that contribute to increased efficiency in industrial processes. For example, in industrial furnaces, in waste heat utilization, or in energy technology.

At the Center HTL, sustainability is not just a buzzword, but an integral part of materials and process development. The goal is to make industrial production more efficient with targeted materials, optimized processes, and a long-term perspective.

InCoKer offers direct added value for companies that use ceramic components under high mechanical, thermal, or chemical loads:

The materials are specifically designed for specific application conditions. Through the use of digital development tools (Integrated Computational Materials Engineering, ICME), material properties can be simulated top-down and designed in a targeted manner. This is made possible by digital material models, simulation-supported process design, and new material combinations that can be adapted to specific applications.

This offers a particular advantage for SMEs:

Shorter development times, less waste, better predictability, and practical tools that can be integrated into existing processes. This saves development time, reduces waste, and lowers unit costs. Particularly relevant for efficient SMEs.

In addition, demonstrators, tools, and methods are being developed that can be transferred directly into industrial process chains without the lengthy transfer from basic research. The participating partners gain access to newly developed materials, simulation apps, and individual support for introduction into their own production.

Your expert is:
Marina Stepanyan, Project manager