Project

CARCIM - Integration of Two-Component Ceramic Injection Moulding for Large-Scale Production of Novel Multifunctional Ceramic Components for Automotive and Railway Applications

Funding origin:

European

STRIA Roadmaps:

Vehicle design and manufacturing (VDM)

Transport mode:

Multimodal

Transport sectors:

Passenger transport

Freight transport

CORDIS link: https://cordis.europa.eu/project/id/31462

Duration:

Start date: 01/09/2006,

End date: 31/08/2009

Status: Finished

Funding details:

Total cost:

€3 743 566

EU Contribution:

€2 000 000

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Overview

Objectives:

The main goal of the CARCIM project was the integration of the two-component ceramic injection moulding (2C-CIM) as a low-cost and large-series production technique for development of complex shaped ceramic components for automotive and railway applications offering a high degree of structural and functional integrity.

Methodology:

To achieve the main project goal the following tasks had to be fulfilled:

specifying four functional components as case studies including material choice and freezing of the final design;
adaptation of powder surface properties to the requirements of feedstock production;
development and supply of new feedstock suitable for low/high pressure 2C-CIM and environmental-friendly debinding processes;
linking of tools for simulation techniques of 2C-CIM parts enclosing the complete processing chain, i.e. tool design, injection moulding, debinding and co-sintering processes;
design and construction of a 2C-CIM tool for testing parts;
establishing of a test rig for non-destructive testing (NDT) by thermography for injection moulded ceramic green parts;
to develop debinding concepts for co-debinding of the feedstock couples;
to predict final distortion of testing and prototype parts after sintering by FEM analysis;
to develop testing samples by high and low pressure 2C-CIM and to characterise these parts;
to produce powders and feedstock couples with refined properties according to the results achieved the testing parts;
to design prototype parts and to simulate the mould filling process for these parts;
to design and to construct tools for the four prototype components;
to develop prototype parts by high and low pressure 2C-CIM;
to fix the final composition of the feedstock systems for large-scale production of the prototype parts;
to investigate the prototype parts in the green and in the sintered state by non-destructive testing methods;
to establish technical guidelines for high-volume production of the case study components;
to test the prototypes under practically relevant conditions;
to estimate the production costs for the specified components;
to validate and to verify the results of the simulations results of the different processing steps;
to perform a comparison between traditionally used materials and the ceramic materials chosen for the ceramic components with respect to the main environmental impact and
to organise two technical workshops.

Integration of Two-Component Ceramic Injection Moulding for Large-Scale Production of Novel Multifunctional Ceramic Components for Automotive and Railway Applications

Overview

Objectives:

Methodology:

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