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Ceramic Applications in the Automotive Industry

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Ceramic Applications in the Automotive Industry Ceramic Applications in the Automotive Industry Michael. J. Hoffmann Institute for Applied Materials - Ceramics in Mechanical Engineering S E KIT – University of the State of Baden-Württemberg and National Large-scale Research Center of the Helmholtz Association www.kit.edu CeramicsCeramics components components in in automotive automotive applications applications filter, catalyst carrier fuel injectors high pressure pump electronic device Functional Ceramics spark andknocking glow sensor plugs, oxygen sensor, knocking sensor, parking distance control, PTC heaters, fuel injection systems PTC heater 1 Institute for Applied Materials- Ceramics in Mechanical Engineering CeramicsCeramics components components in in automotive automotive applications applications filter, catalyst carrier fuel injectors high pressure pump electronic device Structural Ceramics pump componentsknocking sensor (sealings), brake discs, catalyst support, particulate filter, PTC heater 2 Institute for Applied Materials- Ceramics in Mechanical Engineering ProjectionProjection of of Total Total Energy Energy Demand Demand and and Energy Energy Mix Mix • Liquid fuels will still significantly contribute to up-coming energy demands • Combustion engines are necessary in the next decades • Individual transport: long range distance, trucks, hybrids 3 Institute for Applied Materials- Ceramics in Mechanical Engineering EuropeanEuropean Fuel-Economy Fuel-Economy Goal Goal up up to to 2025 2025 150 37,3 mpg 140 130 42 mpg 120 110 100 57,4 mpg US Goal: 100 g/km Emission [g/km] 2 90 CO 80 70 78,4 mpg 60 2010 2015 2020 2025 2030 Year Goal can only be obtained by more efficient combustion engines → Downsizing concept (smaller, but more efficient engines) 4 Institute for Applied Materials- Ceramics in Mechanical Engineering DownsizingDownsizing concept concept Downsizing is based on the principle of a reduction in engine size in order to reduce consumption without affecting power. Measures: - Reduction of number of cylinders - Supercharging (use compressed air) - Direct injection systems Challenges and Needs: - Injection control system - High pressure fuel pump - High thermal and mechanical loading Downsizing can reduce the CO2 emissions between 5% for diesel models and 40% for gasoline models by 2020. These engines should be able to remain dominant for a long time in the car market. 5 Institute for Applied Materials- Ceramics in Mechanical Engineering DownsizingDownsizing concept concept Downsizing is already reality in the present US market 6 Institute for Applied Materials- Ceramics in Mechanical Engineering OutlineOutline • High pressure pump systems for gasoline engines • Spark plugs • Porous ceramics for local reinforcement of metal matrix composites • Piezoelectric injection systems • PTC heating elements • General conclusions 7 Institute for Applied Materials- Ceramics in Mechanical Engineering PiezoelectricPiezoelectric Driven Driven Common Common Rail Rail Fuel Fuel Injection Injection Technology Technology high pressure pump fuel injector electronic device courtesy: Robert Bosch GmbH Piezo technology increases efficiency and reduces emission → already used in Diesel systems, but with a high potential for gasoline systems 8 Institute for Applied Materials- Ceramics in Mechanical Engineering PiezoelectricPiezoelectric Driven Driven Common Common Rail Rail Fuel Fuel Injection Injection Technology Technology metal parts ceramic parts -40 % Pfister et al. Cer. Trans. (2011) High fuel injection pressure is needed to reduce droplet size (-40%), → decrease of fuel consumption and pollutant emissions (-80%) 9 Institute for Applied Materials- Ceramics in Mechanical Engineering FuelFuel evaporation evaporation in in combustion combustion chamber chamber source: Spicher, KIT-IFKM 10 Institute for Applied Materials- Ceramics in Mechanical Engineering 3-Piston3-Piston High High Pressure Pressure Pump Pump for for Gasoline Gasoline Engines Engines KIT / IFKM, Pfister, Spicher Cam/sliding-shoe contact is tribological highly loaded due to an insufficient lubrication of petrol with increasing pressure → ceramic components can be a solution 11 Institute for Applied Materials- Ceramics in Mechanical Engineering FrictionFriction coefficient coefficient in in the the cam/sliding-shoe cam/sliding-shoe contact contact SSiC / SSiC SiAlON / SiAlON Pfister et al. Cer. Trans. (2011) Silicon carbide and SiAlONs indicate a similar behaviour with a very low friction coefficients at a system pressure of 50 MPa 12 Institute for Applied Materials- Ceramics in Mechanical Engineering EffectEffect of of surface surface texturing texturing of of the the cam/sliding-shoe cam/sliding-shoe contact contact -75 % Pfister et al. Cer. Trans. (2011) The texture significantly improves the performance of self-mated silicon carbide at low speed or low contact force 13 Institute for Applied Materials- Ceramics in Mechanical Engineering OutlineOutline • High pressure pump systems for gasoline engines • Spark plugs • Porous ceramics for local reinforcement of metal matrix composites • Piezoelectric injection systems • PTC heating elements • General conclusions 14 Institute for Applied Materials- Ceramics in Mechanical Engineering GasolineGasoline direct direct injection injection system system Source: KIT / IFKM, Spicher An ignitable mixture for low and high loads is only formed in a very narrow spatial zone 15 Institute for Applied Materials- Ceramics in Mechanical Engineering FutureFuture trends trends for for spark spark plugs plugs in in fuel-efficient fuel-efficient engines engines Microstructure with a glassy phase and pores 4 µm Challenges • Distance between electrodes will increase • Higher voltage will be applied → longer spark • Pressure increase in combustion chamber → higher thermal and mechanical loading • reduction in size 16 Institute for Applied Materials- Ceramics in Mechanical Engineering StrengthStrength distribution distribution and and typical typical failure failure mechanisms mechanisms ofof commerical commerical spark spark plugs plugs compaction defects Manufacturer Strength distribution reflects also the electric breakthrough behaviour → Most current commercial materials do not match the requirements 17 Institute for Applied Materials- Ceramics in Mechanical Engineering FutureFuture trends trends for for spark spark plugs plugs in in fuel-efficient fuel-efficient engines engines Challenges: • smaller diameter → higher thermal and mechanical loading → strength must be increased by enhanced processing conditions • adjustable resistance • high voltage → increase in electrical breakthrough 18 Institute for Applied Materials- Ceramics in Mechanical Engineering OutlineOutline • High pressure pump systems for gasoline engines • Spark plugs • Porous ceramics for local reinforcement of metal matrix composites • Piezoelectric injection systems • PTC heating elements • General conclusions 19 Institute for Applied Materials- Ceramics in Mechanical Engineering MetalMetal Matrix Matrix Composites Composites for for Highly Highly Loaded Loaded Engine Engine Parts Parts Engine part manufactured by pressure die casting of Al-based alloys after German, 1994 Inhomogeneous cooling causes thermal stresses that can be minimized by a local reinforcement with ceramics (preform concept). 20 Institute for Applied Materials- Ceramics in Mechanical Engineering LocalLocal reinforcement reinforcement of of pressure pressure die-casted die-casted Al-MMCs Al-MMCs local reinforcement (cermic preform) 21 Institute for Applied Materials- Ceramics in Mechanical Engineering PreparationPreparation of of Porous Porous Ceramic Ceramic Preforms Preforms Pore filler concept Freeze casting Ceramic foams 40 µm 100 µm 250 µm Porosity: up to 75% Porosity: 20-85% Porosity: 85-95% Pore size and shape Ice crystals form final cell size depends on depend on filler pores polymer foam Mattern et al., JECS (2004). Different types of ceramic preforms can be manufactured by using powder technology processes. 22 Institute for Applied Materials- Ceramics in Mechanical Engineering PreparationPreparation of of freeze-casted freeze-casted Al-MMCs Al-MMCs 100 µm ceramic wall Ice lamella Cooled plate Waschkies et al., JACS (2009) 2 mm S. Roy & A. Wanner, Compos. Sci. Technol. (2008) 23 Institute for Applied Materials- Ceramics in Mechanical Engineering EstimationEstimation of of failure failure probabili probabilityty for for different different perform perform types types 1E-9 foams . MPa] 2 1E-10 freeze casting 1E-11 Survival region . with pore fillers 1E-12 Failure region permeability strength [m strength permeability 1E-13 pressure 0,01squeeze 0,1 1 10 castingeffective melt velocity [m/s]casting Mattern et al., JECS (2004). Freeze casted preforms can be used for pressure casting, while preforms with pore fillers and bottle neck pores will break 24 Institute for Applied Materials- Ceramics in Mechanical Engineering OutlineOutline • High pressure pump systems for gasoline engines • Spark plugs • Porous ceramics for local reinforcement of metal matrix composites • Piezoelectric injection systems • PTC heating elements • General conclusions 25 Institute for Applied Materials- Ceramics in Mechanical Engineering MechanismsMechanisms of of high high field field strain strain in in ferroelectric ferroelectric ceramics ceramics Piezoelectric effect (intrinsic) Strain behaviour dhkl dhkl E-Feld S Domain switchung (extrinsic) E ∆L E-Feld → High strain materials rely on both intrinsic and extrinsic effect 26 Institute for Applied Materials- Ceramics
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