Periodic Reporting for period 3 - CEM-WAVE (Novel Ceramic Matrix Composites produced with Microwave assisted Chemical Vapour Infiltration process for energy-intensive industries)
Reporting period: 2023-04-01 to 2024-09-30
CEM-WAVE is an acronym that stands for Novel Ceramic Matrix Composites produced with Microwave-assisted Chemical Vapour Infiltration process for energy-intensive industries. The CEM-WAVE project aims at introducing an innovative production process for Ceramic Matrix Composites (CMCs), which will favour their widespread usage in energy-intensive industries, focusing in particular to steelmaking applications.
This novel process is based on a Microwave-assisted Chemical Vapor Infiltration (MW-CVI) process implemented with the latest MW solid-state sources as an economic and sustainable alternative to reduce the processing costs of CMCs components. To validate the MW-CVI process, a CMC-based prototype will be developed and tested within a pilot-scale radiant tube furnace in an active steelmaking plant. This prototype is a future candidate to replace the metallic materials currently employed in steelmaking, particularly considering the upcoming gradual transition to renewable energy sources (i.e. hydrogen).
The CEM-WAVE project answers the European market growing need for novel materials that can withstand the fluctuating and harsh energy conditions created while using renewable sources. In this sense, it supports the ambitious strategic plan set by the European Green Deal.
Among others, CEM-WAVE’s most important objectives include:
- Improving energy efficiencies in steelmaking production up to 30%, with a reduction in costs ranging between 7 and 13% given the higher thermomechanical performance of CMC materials;
- Reducing the process CO2 emissions up to 20% per kg of CMCs produced;
- Improving the lifetime of radiant tube furnaces of up to 20% compared to the current average, which is between 4 and 8 years.
This novel process is based on a Microwave-assisted Chemical Vapor Infiltration (MW-CVI) process implemented with the latest MW solid-state sources as an economic and sustainable alternative to reduce the processing costs of CMCs components. To validate the MW-CVI process, a CMC-based prototype will be developed and tested within a pilot-scale radiant tube furnace in an active steelmaking plant. This prototype is a future candidate to replace the metallic materials currently employed in steelmaking, particularly considering the upcoming gradual transition to renewable energy sources (i.e. hydrogen).
The CEM-WAVE project answers the European market growing need for novel materials that can withstand the fluctuating and harsh energy conditions created while using renewable sources. In this sense, it supports the ambitious strategic plan set by the European Green Deal.
Among others, CEM-WAVE’s most important objectives include:
- Improving energy efficiencies in steelmaking production up to 30%, with a reduction in costs ranging between 7 and 13% given the higher thermomechanical performance of CMC materials;
- Reducing the process CO2 emissions up to 20% per kg of CMCs produced;
- Improving the lifetime of radiant tube furnaces of up to 20% compared to the current average, which is between 4 and 8 years.
In CEM-WAVE, after achieving optimized oxide and non-oxide preforms through FHF’s processes in WP1, WP2 focused on characterizing SiCf/SiC preforms and refining MW heating. IPCF-CNR conducted high-temperature dielectric characterization, while Certimac-ENEA and CNRS integrated thermal diffusivity and emissivity data into multiphysics models to optimize MW heating parameters. CNRS further explored MW-CVI’s unique "inside-out" densification.
WP3 advanced CMC processing using MW-CVI technology. UNIPI, supported by IPCF-CNR, successfully infiltrated square and tubular SiCf/SiC preforms, demonstrating MW solid-state sources' efficiency. IPCF-CNR’s Multiport-Multifrequency approach improved heating uniformity and matrix infiltration, later validated in a JECS publication.
WP4 evaluated material performance, with ENEA conducting extensive characterizations on high-temperature aging and corrosion resistance. Steelmaking environment simulations confirmed durability, while FE models optimized material design.
WP5 enhanced computational modeling and AI integration. CNRS developed 3D computational models based on μCT and SEM data, refining property predictions. A 2D meshing procedure improved image analysis, while a Random Forest-based AI tool enhanced material behavior forecasting. FreeFEM++ scripts enabled advanced 3D simulations.
WP6 explored joining technologies and EBCs. POLITO led plasma surface treatments, improving bonding strength, while two tailored EBC coatings for oxide and non-oxide CMCs were successfully tested. Findings were published in JECS.
WP7 transitioned research to industrial validation. FHF and ATL developed hybrid manufacturing routes for CMC tubes, tested under real conditions at AMIII. The prototypes withstood 900-1100°C in hydrogen firing, monitored via advanced thermal imaging. Post-test analyses confirmed minimal degradation, proving their feasibility for steelmaking.
WP8 assessed sustainability and economic feasibility. UNIPI took over LCA, LCC, and TA activities, using SymaPro software to confirm MW-CVI’s environmental and cost benefits. A risk assessment identified and mitigated potential barriers.
WP9 focused on dissemination and innovation management, with partners engaging in conferences, publications, and industry collaborations. A Multistakeholder Platform and open-access research facilitated knowledge transfer and commercialization.
The project’s key outcomes were highly promising. CMC prototypes—Al2O₃f/AlPO₄/Al2O₃ and SiCf/(SiC/BN)₃/SiC with YAS-based EBC—survived real-world high-temperature tests, proving their industrial viability. These materials could cut CO2 emissions in steelmaking by 20%, driving sustainability.
MW-CVI technology proved groundbreaking, reducing processing time tenfold. The multi-kW solid-state MW source system enhanced frequency control and energy efficiency, optimizing production. Pre-preg techniques led to high-strength Al2O₃-based CMCs, while braided CMCs and SiC-CVI joining innovations facilitated complex structures.
Breakthroughs in joining and coating technologies resulted in YAS-based and glass-ceramic materials withstanding 900-1200°C. DLI-CVD EBCs provided superior environmental protection.
CEM-WAVE demonstrated that CMCs can replace metal alloys in demanding applications, enhancing durability, efficiency, and sustainability. By integrating MW-CVI, AI-driven optimization, and advanced materials, the project has paved the way for a greener, cost-effective future in high-temperature industries, with potential applications in steelmaking, aerospace, and hydrogen energy.
WP3 advanced CMC processing using MW-CVI technology. UNIPI, supported by IPCF-CNR, successfully infiltrated square and tubular SiCf/SiC preforms, demonstrating MW solid-state sources' efficiency. IPCF-CNR’s Multiport-Multifrequency approach improved heating uniformity and matrix infiltration, later validated in a JECS publication.
WP4 evaluated material performance, with ENEA conducting extensive characterizations on high-temperature aging and corrosion resistance. Steelmaking environment simulations confirmed durability, while FE models optimized material design.
WP5 enhanced computational modeling and AI integration. CNRS developed 3D computational models based on μCT and SEM data, refining property predictions. A 2D meshing procedure improved image analysis, while a Random Forest-based AI tool enhanced material behavior forecasting. FreeFEM++ scripts enabled advanced 3D simulations.
WP6 explored joining technologies and EBCs. POLITO led plasma surface treatments, improving bonding strength, while two tailored EBC coatings for oxide and non-oxide CMCs were successfully tested. Findings were published in JECS.
WP7 transitioned research to industrial validation. FHF and ATL developed hybrid manufacturing routes for CMC tubes, tested under real conditions at AMIII. The prototypes withstood 900-1100°C in hydrogen firing, monitored via advanced thermal imaging. Post-test analyses confirmed minimal degradation, proving their feasibility for steelmaking.
WP8 assessed sustainability and economic feasibility. UNIPI took over LCA, LCC, and TA activities, using SymaPro software to confirm MW-CVI’s environmental and cost benefits. A risk assessment identified and mitigated potential barriers.
WP9 focused on dissemination and innovation management, with partners engaging in conferences, publications, and industry collaborations. A Multistakeholder Platform and open-access research facilitated knowledge transfer and commercialization.
The project’s key outcomes were highly promising. CMC prototypes—Al2O₃f/AlPO₄/Al2O₃ and SiCf/(SiC/BN)₃/SiC with YAS-based EBC—survived real-world high-temperature tests, proving their industrial viability. These materials could cut CO2 emissions in steelmaking by 20%, driving sustainability.
MW-CVI technology proved groundbreaking, reducing processing time tenfold. The multi-kW solid-state MW source system enhanced frequency control and energy efficiency, optimizing production. Pre-preg techniques led to high-strength Al2O₃-based CMCs, while braided CMCs and SiC-CVI joining innovations facilitated complex structures.
Breakthroughs in joining and coating technologies resulted in YAS-based and glass-ceramic materials withstanding 900-1200°C. DLI-CVD EBCs provided superior environmental protection.
CEM-WAVE demonstrated that CMCs can replace metal alloys in demanding applications, enhancing durability, efficiency, and sustainability. By integrating MW-CVI, AI-driven optimization, and advanced materials, the project has paved the way for a greener, cost-effective future in high-temperature industries, with potential applications in steelmaking, aerospace, and hydrogen energy.
The CEM-WAVE project is poised to make a significant impact, fully aligning with SPIRE-08-2020 objectives.
- Energy Efficiency & CO2 Reduction
CEM-WAVE enhances energy efficiency by at least 30% while cutting CO2 emissions and resource use by 20%. By integrating CMC-based components in radiant tube furnaces, the project addresses decarbonization in the energy-intensive steel industry. CMCs’ superior thermal efficiency and durability enable substantial energy savings and emission reductions, supporting sustainable steel production.
- Extended Equipment Lifetime & Cost Savings
CEM-WAVE innovations extend industrial equipment lifespan by 20%, minimizing downtime and maintenance costs. Key performance metrics include heat transfer efficiency, high-temperature resilience, and corrosion resistance. Real-environment health monitoring ensures optimal CMC performance, while advancements in joining and coating facilitate complex CMC structures, improving maintenance efficiency.
- Broader Industrial Impact
CMCs are gaining traction in aerospace, automotive, and energy sectors, with rising demand in electric vehicles. By proving their efficiency in radiant tube furnaces, CEM-WAVE paves the way for higher annealing temperatures, new processing chemistries, and advanced manufacturing, strengthening industrial competitiveness.
- Economic & Environmental Benefits
CEM-WAVE’s cost-effective approach accelerates CMC adoption across industries, delivering both economic gains and environmental benefits, reinforcing sustainability and innovation.
- Energy Efficiency & CO2 Reduction
CEM-WAVE enhances energy efficiency by at least 30% while cutting CO2 emissions and resource use by 20%. By integrating CMC-based components in radiant tube furnaces, the project addresses decarbonization in the energy-intensive steel industry. CMCs’ superior thermal efficiency and durability enable substantial energy savings and emission reductions, supporting sustainable steel production.
- Extended Equipment Lifetime & Cost Savings
CEM-WAVE innovations extend industrial equipment lifespan by 20%, minimizing downtime and maintenance costs. Key performance metrics include heat transfer efficiency, high-temperature resilience, and corrosion resistance. Real-environment health monitoring ensures optimal CMC performance, while advancements in joining and coating facilitate complex CMC structures, improving maintenance efficiency.
- Broader Industrial Impact
CMCs are gaining traction in aerospace, automotive, and energy sectors, with rising demand in electric vehicles. By proving their efficiency in radiant tube furnaces, CEM-WAVE paves the way for higher annealing temperatures, new processing chemistries, and advanced manufacturing, strengthening industrial competitiveness.
- Economic & Environmental Benefits
CEM-WAVE’s cost-effective approach accelerates CMC adoption across industries, delivering both economic gains and environmental benefits, reinforcing sustainability and innovation.