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.
