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Innovative Value Chains for European Ceramic Oxide Fibres

Periodic Reporting for period 1 - InVECOF (Innovative Value Chains for European Ceramic Oxide Fibres)

Periodo di rendicontazione: 2022-05-01 al 2023-10-31

The demand for oxide fibers for CMC applications in Europe has been growing, driven by the need for lightweight and durable materials in various industries. Oxide fibers, such as silicon carbide and alumina, play a crucial role in reinforcing CMCs, enhancing their overall performance in extreme environments.
1. Identifying and Developing Fibers: The project aims to identify or develop oxide fibers that meet the specific requirements for CMC applications. This involves researching and optimizing the properties of various oxide materials to enhance their suitability for the intended use.
2. Fiber Production: Establishing a reliable source of oxide fibers within Europe is a critical objective. This may involve setting up or collaborating with existing facilities for the large-scale production of oxide fibers, ensuring a stable and efficient supply chain.
3. Weaving and CMC Fabrication: The consortium covers the entire process chain, including the weaving of oxide fibers into preforms and the fabrication of CMC components. This step involves the integration of fibers into a matrix material, typically a ceramic, to create composite structures with tailored properties.
4. Testing of CMC Demonstrators: Rigorous testing of CMC demonstrators is a crucial aspect of the project. This includes assessing the mechanical, thermal, and chemical properties of the CMC materials to ensure they meet the stringent requirements for specific applications, such as in aerospace or energy systems.
The Pathway to Impact is followed:
1. Research and Development:The project begins with extensive research to identify or develop oxide fibers with optimal properties. This includes collaboration between experts in materials science, chemistry, and engineering.
2. Production Optimization: Once suitable fibers are identified, the focus shifts to optimizing their production processes to ensure scalability, cost-effectiveness, and consistency in quality.
3. Collaborative Consortium: The consortium brings together expertise from various stages of the supply chain, fostering collaboration between fiber developers, producers, weavers, and CMC fabricators. This ensures a seamless integration of processes and knowledge transfer.
4. Market Access: Establishing a European supplier for oxide fibers enhances regional self-sufficiency and reduces dependence on external sources. This has economic benefits and strengthens Europe's position in the global market for advanced materials.
5. Technology Transfer: The project's success relies on transferring technology from research to industry. By integrating the entire process chain within the consortium, knowledge and innovations can be effectively disseminated.
6. Commercialization and Impact: Successfully producing and testing CMC demonstrators opens avenues for commercialization. Industries in aerospace, energy, and other sectors can benefit from the advanced CMC materials, contributing to technological advancements and economic growth.
In summary, InVECOF aims to address the increasing demand for oxide fibers in CMC applications in Europe by establishing a comprehensive consortium that covers the entire process chain from fiber development to the testing of CMC demonstrators. This project not only seeks to meet the current demand but also positions Europe as a key player in the global market for advanced materials.
Activities Performed:
1. Oxide Fiber Development:
- Extensive research was conducted to identify or develop the next generation of oxide fibers for Ceramic Matrix Composite (CMC) applications.
- Chemical composition studies were carried out to determine the optimal mix of materials for enhanced performance.
2. Spinning Dopes Preparation:
- The first spinning dopes were prepared based on the determined chemical composition of the oxide fibers.
- The spinning dope is a solution containing the precursor materials that can be spun into fibers.
3. Lab Scale Testing:
- The first lab-scale tests were performed to assess the initial properties of the developed oxide fibers.
- This involved analyzing mechanical, thermal, and chemical characteristics to evaluate the fibers' suitability for CMC applications.
4. Lab Scale Fiber Production:
- Lab-scale fibers of corundum and mullite were successfully produced using Hydrothermal Liquefaction (HTL) and Rath's manufacturing process.
- This step demonstrates the viability of the developed spinning dopes and the scalability of the fiber production process.
5. Technical Scale Fiber Production:
- Scaling up the production process, mullite fibers were successfully manufactured at a technical scale.
- This is a crucial milestone, indicating the feasibility of large-scale oxide fiber production.
6. Fiber Pilot Plant Operation:
- The Hydrothermal Liquefaction (HTL) fiber pilot plant was put into operation.
- The pilot plant allows for a more significant volume of oxide fiber production, bridging the gap between lab-scale testing and full-scale production.
7. successful Spinning and Calcination:
- The first spinning dope was prepared for the fiber pilot plant.
- Fibers were successfully spun and calcinated, indicating the reproducibility of the process on a larger scale.
Main Achievements:
1. Lab and Technical Scale Fiber Production:
- Successful production of lab-scale fibers from corundum and mullite and technical-scale mullite fibers showcases the scalability and reliability of the manufacturing process.
2. Pilot Plant Operation:
- The operational fiber pilot plant represents a significant achievement in the project, enabling larger-scale production for testing and potential commercialization.
3. Successful Spinning and Calcination:
- The successful spinning and calcination of fibers at both lab and pilot scales validate the effectiveness and reproducibility of the developed spinning dopes and manufacturing processes.
1. Seeding for Alumina Fibers:
- Seeding techniques for corundum fibers were identified and implemented.
- Corundum seeding is a critical step in the development of alumina fibers with desired properties.
2. Chemical Composition Determination:
- The chemical composition of the next generation oxide fibers was identified, laying the foundation for further development.
3. Zirconia Doping Improvements:
- The introduction of zirconia doping to mullite fibers demonstrated an increase in creep stability, enhancing the mechanical properties of the fibers.
fibre handling after sintering
Photo of ceramic oxide fibers after different process steps
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