Currently funded project

Development of a basalt fibre-reinforced mixed oxide ceramic using the example of a hand casting crucible (BaMOX)

Motivation

Metallic hand pouring pots in use
© Fraunhofer-Centre HTL
Metallic hand pouring pots in use

With a share of 88%, aluminium casting currently dominates non-ferrous metal casting production. The trend towards energy-saving cars, new applications in e-mobility and efficient material cycles will further increase the use of aluminium. At present, hand casting crucibles and other production aids such as casting troughs, tundishes and moulds made of metallic and ceramic materials are used for the transport and processing of aluminium melts. However, these materials have weak points: the high wear and tear of the metallic hand casting crucibles is a serious problem. This not only results in high repair costs but also impairs ongoing production.

 

Objective

Basalt fibre fabric
© Fraunhofer-Centre HTL
Basalt fibre fabric

 

An alternative is handmade crucibles made of fibre-reinforced oxidic ceramic. These have a longer service life and higher operational safety. There are currently two established systems: Al2O3-SiO2 matrices reinforced with Al2O3 or SiO2 fibres and CaSiO3 matrices reinforced with SiO2 fibres. However, these materials are very expensive, mainly due to the high price of ceramic fibres. Therefore, the aim is to develop a ceramic fibre composite material (CMC) which meets the requirements of the casting process and is far more cost-effective to produce than the alternative materials used so far.

Approach

Technological development of a manual casting crucible made of GMC
© Fraunhofer-Centre HTL
Technological development of a manual casting crucible made of GMC

Basalt fibre reinforced geopolymers (GMCs) have very low raw material costs and therefore represent a highly interesting material for the entire light metal casting industry.

The following work steps are planned for development:

  • Evaluation of the basalt fibre qualities
  • Textile processing of the fibres
  • Development of suitable geopolymer
  • Development of a fibre coating to control the fibre-matrix properties
  • Production of sample CMCs
  • Characterisation of BF-CMCs
  • Development of a suitable large-scale process
  • Tool and component manufacturing
  • Application and characterisation in the aluminium foundry

Project Data

Project Duration 01.07.2020 - 31.06.2023
Sponsor Central Innovation Programme for SMEs (ZIM)
Funding Amount 100,600 Euro
Project Partners Fraunhofer-Centre HTL
InovaCeram
Metallgießerei Chemnitz GmbH
Technische Universität Chemnitz
Project Coordination Andrea Preuß (TU Chemnitz)
Project Management at the HTL Peter Vierhaus