Radically innovative technology for efficient manufacturing of preforms for ceramic matrix composite (CMC) brake disks

Project Information

ROLL-IT

Grant agreement ID: 826760

DOI

10.3030/826760

Project closed

EC signature date 31 July 2018

Start date 1 August 2018

End date 30 November 2018

Funded under

• INDUSTRIAL LEADERSHIP - Innovation In SMEs

Total cost

€ 71 429,00

EU contribution

€ 50 000,00

Coordinated by

PETROCERAMICS SPA
Italy

Periodic Reporting for period 1 - ROLL-IT (Radically innovative technology for efficient manufacturing of preforms for ceramic matrix composite (CMC) brake disks)

Reporting period: 2018-08-01 to 2018-11-30

Summary of the context and overall objectives of the project

Light weight vehicle design is a keystone to improving fuel efficiency and eco-friendliness in vehicles. Adoption of advanced lightweight ceramic composites as opposed to cast iron, can lead to a radical weight reduction in vehicle components like the braking system. CMC brakes are 60% lighter than cast iron discs and their adoption could save 25kg/car. In addition, CMC brakes reduce particle emissions by 90%, with no emissions of heavy metals.

Hot Press Moulding is the most used technique for CMC brakes manufacturing nowadays. However, it is also one of the primary limiting factors in its adoption. It has several manual steps performed by specialized operators, which raises the production costs. It has a low throughput, high fault rate, high energy consumption rate and uses a lot of raw materials, leading to high production costs. Additionally, the technique does not optimise the fibre orientations during production which yields poor mechanical and thermal properties.

Within this project, Petroceramics is aiming at taking ROLL-IT into the market. ROLL-IT is a fully automated process that combines advanced additive manufacturing techniques with traditional sheet moulding, enabling a continuous and automated forming process of near-to-shape preforms for CMC brake disks. The approach will be particularly suitable to optimize production resources reducing wastage, time, materials and energy and tune the mechanical properties of the final product. Specifically, ROLL-IT will enable absolute control of the reinforcing fibre topology and material properties that mainly affect the disc performances.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

During this project, Petroceramics has carried out an extensive feasibility study of both technical and commercial aspects affecting ROLL-IT development.

On the technical side, the company has identified the requirements for the optimisation and scaling-up of the machine. Laser cutting options were tested in terms of speed and performance and its compatibility with other machine components was assessed.

On the commercial side, the company investigated the market and identified the main barriers that ROLL-IT may face during its commercialisation. The IPR landscape was analysed and risks the risks that may prevent ROLL-IT from a successful market uptake were described. Mitigation actions were also defined. Finally, Petroceramics consolidated the information from the market research and prepared a 5-years financial projection.

Although the laser cutting resulted not feasible, other mechanical methods for cutting were identified. Given the results from the study, Petroceramics concluded to continue with the project to make ROLL-IT market ready by 2021.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

The few companies that produce CMC brake discs mostly use Hot Press Moulding, which is the only affordable preforming technique at an industrial level so far. ROLL-IT is an all-inclusive, cost effective, innovative migration from cast iron brake discs to CMC brake discs for the automotive industry and vehicles of the future.

Unlike Hot Press Moulding, ROLL-IT increases by 600% production performance and reduces energy costs by 45%. It allows to achieve a 60-70% reduction in defects owing to the replacement of manual operations with automated controlled processes and improves mechanical properties of the disks, thus reducing braking distance by 40%, enhancing driver’s safety. These benefits make possible a 50% reduction in the production costs for a sales price 43% cheaper.

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