Evaluation of the Technical-Economic Potential of Thermosetting Injection Moulding for Shaping of C/C-SiC-Ceramics

Abstract

Ceramic-matrix composites (CMC) made of carbon and silicon carbide dual matrix reinforced with carbon fibres (C/C-SiC) offer some technical advantages like exceptional heat, thermal shock, creep, wear resistance, and no fine dust load, while also having low density and high strength. Showing these excellent properties, this material is well established in high-performance brake applications, e. g. in luxury cars or elevators. However, the industrial production process of this material is still not applicable for mass production. Due to high production costs, a broad application of this material in products like brake discs in standard passenger cars is not feasible at the moment. To exploit the technical and economic potentials and realise a broader market penetration, the thermosetting injection moulding process presented in this paper is explored as a shaping process of the carbon fibre reinforced plastic (CFRP) moulded body. In this way, a fully automated and high-volume production can be realised. From the economic point of view, the option of introducing a large-scale manufacturing process bears the potential of achieving considerable cost improvements. To assess and demonstrate the potentials of C/C-SiC shaped by thermosetting injection moulding and their chances for market penetration, a holistic technical-economic evaluation is necessary. The paper demonstrates a methodology for an integrated evaluation from a technical as well as an economic view and applies it to C/C-SiC and thermosetting injection moulding. By revealing the potentials, it contributes to the broad application of products made of C/C-SiC in the future.