Currently funded project

The production of ceramics and sintered metals is very energy-intensive due to the high-temperature processes required, so that large amounts of primary energy can be saved by optimising process control. For large and geometrically complex components, it is particularly challenging to develop faster and energy-saving processes without ultimately reducing overall efficiency through increased reject rates due to sinter distortion or component cracks. Since the approach of Industry 4.0 - the workpiece continuously reports its status to an automated process control system - cannot be implemented at temperatures of > 1000°C, alternatives must be found for digitised support of optimised process control.

Using sanitary ceramics as an example, a methodology will be developed and tested to optimise the production of components in terms of energy efficiency and product quality through the interaction of various digital processes. Predictive simulation of the component behaviour in the process (HTL), continuous monitoring of the furnace parameters, industrial image processing for documentation of the setting grids and the establishment of a single item tracking system (industrial partners) will be used. In the end, the energy saving potential of the overall methodology will be demonstrated.

• Detailed in-situ characterisation of ceramic bodies (V&B)
  
• FE modelling and validation of the respective process kinetics
  
• Simulation of component behaviour as a function of the temperature curve T(t)
  
• Development and validation of energetically optomised firing cycles
  
• Analysis (FE-simulation) of the influence of mixed charge or impeded heat transfer in the real furnace situation
  
• Simulation to support error analysis in case of occured component errors correlated with furnace deviations