Shaping

For the shaping of ceramic and powder metallurgical green bodies, classical methods such as cold isostatic pressing, extrusion, slip casting, or wet pressing are available, in addition to 3D printing. Special measurement and simulation methods have been developed for drying. The quality of green bodies is examined using in-house methods and dual-energy computed tomography. The thermal processes for green bodies are carried out in various electric or gas-fired furnaces, where inert, oxidative, or reducing atmospheres as well as vacuum and overpressure can be applied. The optimization of parameters during thermal processes is carried out in a targeted manner using special thermo-optical measurement methods (TOM). For the production of composites, melt infiltration processes can be used. In particular, additively manufactured components have a high potential for post-processing-free production when heat treatment is optimized. If finishing of functional surfaces is necessary, a computer-controlled five-axis machining center is available, among others. Components with complex geometry can be built up from simple components using high-temperature joining techniques. Material and component properties are evaluated using non-destructive methods, material testing methods, and microstructure analyses (see Characterization).

One application focus is high-temperature materials, such as lightweight refractory aids, high-temperature insulation made of foam ceramics, sensor and burner materials, as well as high-temperature joints. Experience also exists in the development of electroceramics, for example for actuators, varistors, insulators, and heat sinks. Additionally, cutting and structural materials are being developed.

• Identification of suitable materials for customer-specific applications: oxide ceramics, non-oxide ceramics, silicate ceramics, powder metals, hard metals, fine-grain graphite, and metal-ceramic composites
• Design of components for complex thermomechanical loads (topology optimization)
• Determination of optimal microstructures for customer-specific requirements
• Microstructure analysis with electron microscopy, X-ray diffraction, etc.
• Development of composites with customer-specific mechanical, thermal, and electrical properties
• Powder metallurgical production and optimization of microstructures
• Prototype and small series production of components, also using additive manufacturing
• Design and optimization of heat treatment processes
• Material and component testing