Ceramic Applications in the Automotive Industry

Michael. J. Hoffmann

Institute for Applied Materials - Ceramics in Mechanical Engineering

KIT University of the State of Baden-Wrttemberg and

National Large-scale Research Center of the Helmholtz Association
www.kit.edu
 Ceramics
Ceramicscomponents
componentsininautomotive
automotiveapplications
applications
filter, catalyst carrier
fuel injectors high pressure pump

electronic device

Functional Ceramics
spark and glow sensor
knocking plugs, oxygen sensor,
knocking sensor, parking distance control,
PTC heaters, fuel injection systems

PTC heater

1 Institute for Applied Materials- Ceramics in Mechanical Engineering

 Ceramics
Ceramicscomponents
componentsininautomotive
automotiveapplications
applications
filter, catalyst carrier
fuel injectors high pressure pump

electronic device

Structural Ceramics
pump components (sealings), brake discs,
knocking sensor
catalyst support, particulate filter,

PTC heater

2 Institute for Applied Materials- Ceramics in Mechanical Engineering

 Projection
Projectionof
ofTotal
TotalEnergy
EnergyDemand
Demandand
andEnergy
EnergyMix
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

 European
EuropeanFuel-Economy
Fuel-EconomyGoal
Goalup
upto
to2025
2025

150
37,3 mpg
140
130
CO2 Emission [g/km]

42 mpg
120
110
100
57,4 mpg US Goal: 100 g/km
90
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

 Downsizing
Downsizingconcept
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

 Downsizing
Downsizingconcept
concept

Downsizing is already reality in the present US market

6 Institute for Applied Materials- Ceramics in Mechanical Engineering

 Outline
Outline

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

 Piezoelectric
PiezoelectricDriven
DrivenCommon
CommonRail
RailFuel
FuelInjection
InjectionTechnology
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

 Piezoelectric
PiezoelectricDriven
DrivenCommon
CommonRail
RailFuel
FuelInjection
InjectionTechnology
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

 Fuel
Fuelevaporation
evaporationinincombustion
combustionchamber
chamber

source: Spicher, KIT-IFKM

10 Institute for Applied Materials- Ceramics in Mechanical Engineering

 3-Piston
3-PistonHigh
HighPressure
PressurePump
Pumpfor
forGasoline
GasolineEngines
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

 Friction
Frictioncoefficient
coefficientininthe
thecam/sliding-shoe
cam/sliding-shoecontact
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

 Effect
Effectof
ofsurface
surfacetexturing
texturingof
ofthe
thecam/sliding-shoe
cam/sliding-shoecontact
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

 Outline
Outline

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

 Gasoline
Gasolinedirect
directinjection
injectionsystem
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

 Future
Futuretrends
trendsfor
forspark
sparkplugs
plugsininfuel-efficient
fuel-efficientengines
engines

Microstructure with a glassy phase and pores

4 m

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

 Strength
Strengthdistribution
distributionand
andtypical
typicalfailure
failuremechanisms
mechanisms
ofofcommerical
commericalspark
sparkplugs
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

 Future
Futuretrends
trendsfor
forspark
sparkplugs
plugsininfuel-efficient
fuel-efficientengines
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

 Outline
Outline

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

 Metal
MetalMatrix
MatrixComposites
Compositesfor
forHighly
HighlyLoaded
LoadedEngine
EngineParts
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

 Local
Localreinforcement
reinforcementof
ofpressure
pressuredie-casted
die-castedAl-MMCs
Al-MMCs

local reinforcement
(cermic preform)

21 Institute for Applied Materials- Ceramics in Mechanical Engineering

 Preparation
Preparationof
ofPorous
PorousCeramic
CeramicPreforms
Preforms

Pore filler concept Freeze casting Ceramic foams

40 m 100 m 250 m

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

 Preparation
Preparationof
offreeze-casted
freeze-castedAl-MMCs
Al-MMCs

100 m

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

 Estimation
Estimationof
offailure
failureprobability
probabilityfor
fordifferent
differentperform
performtypes
types

1 E -9

MPa] foams
.
1 E -1 0 freeze casting
2
permeability strength [m

1 E -1 1
Survival region
. with pore fillers
1 E -1 2
Failure region

1 E -1 3
0 ,0 1
squeeze0 ,1 1
pressure
10
casting
e ffe c tiv e m e lt v e lo c ity [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

 Outline
Outline

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

 Mechanisms
Mechanismsof
ofhigh
highfield
fieldstrain
strainininferroelectric
ferroelectricceramics
ceramics

Piezoelectric effect (intrinsic)

Strain behaviour
d hkl d hkl 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 in Mechanical Engineering

 Strain
Strainbehaviour
behaviourof
of aaferroelectric
ferroelectricceramic
ceramicat
at20
20kV/cm
kV/cm

20.000 Volt

0,20 PZT -
0,16
High field strain [%]

1 cm

0,12

0,08 +
20 m strain at 20 kV/cm

80 Volt
0,04
-
80 m
0,00
0,0 0,5 1,0 1,5 2,0 2,5 +
Electric field [kV/mm] 0,16 m strain at 20 kV/cm

Typical strain of a donor-doped Pb(Zr,Ti)O3 ceramic (PZT): 0.15 - 0.2 % at 20-30 kV/cm
Multilayer device

27 Institute for Applied Materials- Ceramics in Mechanical Engineering

 Piezoelectric
PiezoelectricDriven
DrivenCommon
CommonRail
RailFuel
FuelInjection
InjectionTechnology
Technology

electronic
PZT-layers

courtesy: Robert Bosch GmbH

termination
typical driving voltage: 100 V, total strain 20-30 m
internal electrodes (AgPd)

28 Institute for Applied Materials- Ceramics in Mechanical Engineering

 Requirements
Requirementsfor
forpiezoelectric
piezoelectricactuators
actuatorsfor
forfuel
fuelinjection
injectionsystems
systems

cofiring with internal electrodes (multilayer device)

high strain
operating temperatures from -40 to 150 C
small temperature dependence of strain
high reproducibility (mass production)
low cost
challenge: replacement of PZT by lead free ferroelectrics

29 Institute for Applied Materials- Ceramics in Mechanical Engineering

 Comparison
Comparisonof
ofPb(Zr,Ti)O
Pb(Zr,Ti)O33and
andaalead-free
lead-freeceramic
ceramic

E = 2 kV / mm E = 2 kV / mm
RBKNNPSUreferencesamples
1000 600
600
LFL493(ref)
20kV/cm ML172(61mu)

800 500
500 ML503(144mu)

33% 400
400
d33* (pm/V)

* (pm/V)
600

d33*,pm/V
300
300
160%
400

d33
200
200
La-PZT
200
53/47 100
100
(Li,Sb)-doped KNN
53.5/46.5
0 00
0 50 100 150 00 50
50 100
100 150
150
Temperature (C) Temperature,C
Temperature (C)

Lead-free ceramics show a lower strain for a similar electric field strength
and exhibit a much stronger temperature dependence of strain

30 Institute for Applied Materials- Ceramics in Mechanical Engineering

 Outline
Outline

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

31 Institute for Applied Materials- Ceramics in Mechanical Engineering

 Heat
Heatdeficiency
deficiencyfor
forcar
carheating
heatingsystems
systemswith
withefficient
efficientengines
engines

source: eberspcher catem, Germany

The increasing efficiency of fuel saving cars requires a supplementary heat system based
on functional ceramics showing a positive temperature coefficient resistance (PTCR) effect.

32 Institute for Applied Materials- Ceramics in Mechanical Engineering

 PTC
PTCeffect
effectinindonor-doped
donor-dopedBaTiO
BaTiO33-based
-basedceamics
ceamics

250 (Bi0,5K 0,5)

Specific Resistance [/cm]

Curie Temperature TC [C]

7
10 200 (Bi0,5Na 0,5)
6
Pb
10 150
Ca
5
10 100

4
10 50
TC Zr
3
10 0
0 50 100 150 200 250 300 350 400
0 5 10 15 20 25 30 35
Temperature [C]
x [mol %]

PTC-effect is based on the temperature depended potential barrier at the grain

boundary high electrical resistance above TC
The ferroelectric phase equals the charge of the potential barrier below TC
low electrical resistance

33 Institute for Applied Materials- Ceramics in Mechanical Engineering

 BaTiO
BaTiO33-based
-basedPTC
PTCheating
heatingelements
elements

1 Vaporizer
2 Car Heater
3 PTC auxiliary heater

source: eberspcher catem, Germany

Highly efficient cars do not produce enough waste energy for heating

34 Institute for Applied Materials- Ceramics in Mechanical Engineering

 PTC
PTCeffect
effectinindonor-doped
donor-dopedBaTiO
BaTiO33-based
-basedceamics
ceamics

Seat heater for convertibles

OEMs favour different local heating elements to reduce total energy consumption

35 Institute for Applied Materials- Ceramics in Mechanical Engineering

 Outline
Outline

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

36 Institute for Applied Materials- Ceramics in Mechanical Engineering

 Requirements
Requirementsand
andChallenges
Challengesfor
forMaterials
MaterialsResearch
Research

Complexity of requirement profiles for the system

Reliability
Structural
Complexity in materials preparation

Quality
Properties
Costs
Functional Weight
Properties
Composites
Multifunctional
Properties
Multimaterial
Composites

Powder
Thermomechanical Technology
Treatment

37 Institute for Applied Materials- Ceramics in Mechanical Engineering

37 RTC | 06/23/2007 | 2007 Robert Bosch LLC and affiliates. All rights reserved.
 Requirements
Requirementsand
andChallenges
Challengesfor
forProduct
ProductDevelopment
Development

Return
+
Prototype

06 07 08 09 10 11 12 13 14 15

SOP
Reduction of product Reduction of
development time product life cycle

- Support through modeling

and simulation and better
coordination Time

Reduction of product development time due to shorter product life cycles

38 Institute for Applied Materials- Ceramics in Mechanical Engineering

 Modeling
Modelingand
andsimulation
simulationacross
acrossthe
thewhole
wholelength
lengthscale
scale

length scale

10-10 - 10-9 m 10-7 - 10-5 m 10-2 - 10-1 m

courtesy: P.F. Becher

Ab-initio calculations Phase field or vertex dynamic FE-methods for calculation

MD- simulation simulation of coupled loading conditions
New materals Microstrutural design Design optimization

39 Institute for Applied Materials- Ceramics in Mechanical Engineering

 Conclusion
Conclusion

Fixed first idea

from the first idea to the product

Raw project
Board project
Product in the market
Accepted products

Economically successful products

source: Kienbaum, Bullinger

40 Institute for Applied Materials- Ceramics in Mechanical Engineering