Thermal Composites

Alba || Francisco || Moreno

Outline
I. Intro on traditional Thermal Composites and
Applications
II. Pyromeral Thermal composite (Composition
and Processing)
III.Its Properties and Applications
IV.Conclusion

Thermal Composites
composites especially designed for thermal applications
used in ovens, furnaces, suits, aerospace and other
applications requiring strength and stability under intense
heat or cold
most are tailored for high temperature cases

Exhaust System
Piping system used to guide
exhaust gases away from the
combustion in an engine

Materials Criteria for Exhaust Pipe Systems

Ease of Fabrication or Shaping: different
vehicles/engines require different designs of
exhaust pipe systems

Motorcycle

Truck

Two-Stroke engine

Materials Criteria for Exhaust Pipe Systems

High Temperature
Resistance: Material
should not degrade at
the exhaust
temperatures
(gasoline engine:
~850-1000C)
Steel exhaust manifold at 850C

Materials Criteria for Exhaust Pipe Systems

Dimensional
Stability: Material
should not deform or
break at the exhaust
temperatures and
during operation (not
brittle)

Materials Selection for Exhaust Pipes

Material

Ease of
Shaping

High Temp.
Resistance

Dimensional
Stability

Polymer

Metals

Ceramics

Metals are conventionally used!

(but suffer large weight and tedious machining process)

Conventional Materials for Exhaust Systems

Stainless Steels
includes Austenitic Stainless Steels (304, 305) and Low
Carbon Ferritic Stainless Steels (409L, 410L, 430LX)
resistant to high temperature oxidation and high
temperature corrosion
Melting points ~1400C
Density ~8.0g/cm3
Steels are heavy and have tedious machining
and shape-forming processes!
(there is a need for composites!)

Conventional Materials for Exhaust Systems

Stainless Steels
Steel Type

Thermal Conductivity
(W/m K)

Coefficient of Thermal
Expansion (um/m K)

304

16.2

16.9

305

16.2

17.3

409L

24.9

11.7

410L

24.9

9.9

430LX

26.1

10.4

PyroSic and PyroKarb

Composite:
Ease of
shaping
High Temp.
resistance
Dimensional
stability

PyroSic and PyroKarb

Reinforcing element: Silicon
carbide or carbon fiber
meshes impregnated with
Matrix: glass-ceramic
thermosetting inorganic
polymer; SiO2 nanoparticles
with aluminosilicates
(ceramic-ceramic composite)

PyroSic and PyroKarb

Processing:
1. Shaping a shapeable composite material composed of a
textile fibrous reinforcement based on silicon carbide (SiC)
fibre impregnated with a reaction mixture taking the form of
an aqueous composition of alkaline aluminosilicates
2. Obtaining a thermoformed composite element with a fibrous
reinforcement and with a matrix of aluminosilicate oxides by
thermosetting, at a temperature of between 60C and 180C,
the shaped element obtained in step 1

PyroSic and PyroKarb

Processing:
3. Heat-treating at above 600C the thermoformed
composite element in order to convert the matrix into glass
by melting
4. Producing a metal carrier structure connected to the
heat-treated composite element obtained in step 3, the
heat-treated composite element being intended to be in
contact with the exhaust gases

PyroSic Demonstration (1000-1200c

Torch Flame)

http://www.high-temperature-composites.com/video-demo-high-temperature-composite-material.htm

Properties and Applications

Goal: Replace metal (steel, Titanium, Inconel) in EXHAUST SYSTEMS

1. Lightweight/ Lower density

a. more versatile product design
b. higher fuel efficiency
c. easier transport
2. More energy efficient processing
(Requires lower temperature and pressure)
a. more cost effective processing
b. less complicated equipments needed

Titanium Exhaust

CFRP Exhaust Pipe

Summary of Properties

Most important
for Exhaust Pipe
Applications

Main Physical and Thermal Properties of PyroSic Composites:

Property

Value

Density

1.8 to 2.2 g/cm3

Coefficient of Thermal Expansion

3 x 10-6 /K

Thermal Conductivity (through thickness)

0.90 w/m.K

Thermal Conductivity (in plane)

0.95 w/m.K

In comparison with other materials for EXHUAST PIPES:

Ti = 4.5 g/cm3
Inconel = 8.2 g/cm3

>

PyroSic

CTECarbon Steel= 10.8 x 10-6 /K

CTEStainless Steel= 10.1-17.3 x 10-6 /K

>

PyroSic

PyroSic has lower DENSITY and CTE than conventional metals for Exhaust Pipes

Summary of Properties

This thermal composite material can withstand temperatures up to 750 deg. Celsius.
Can effectively retain 95% mechanical properties at short exposures (30 mins)

Applications: Exhaust Pipes

Design Considerations:
- complex design / different
shapes and form
- withstands exhaust
temperature (600- 1000oC)

- withstands very high level of

vibrations
PyroSic Thermal Composite meets the design considerations mentioned above.

Lamborghini's Sesto Elemento (2011)

PyroSic Thermal Composites are now used in Lamborhinis Exhaust Pipe System

Estimated Costs
Pyrosic + processing

US$ 1000 per yard*

*with 0.914 m (1 yd) x 0.914 m (1 yd) x 0.0254 m (1 in) dimension

US$ 47.12 per kg

Titanium (Metal alone)

Steel (Metal alone without processing)

US$ 6610 per 1 kg

US$ 0.48 per 1 kg

http://www.chemicool.com/elements/titanium.html

https://www.quandl.com/c/markets/industrial-metals

Other Potential Areas of Applications:

AEROSPACE

DEFENSE

AUTOMOTIVE

MOTORSPORTS

Common Important Consideration for Materials Design:

WEIGHT

Thermal Composites
PyroSic

PyroKarb

Lightweight (65% reduction), cost-effective and more

versatile replacement materials for metals in high
temperature applications

In conclusion:
Thermal composites offer heat-resistant
materials with better properties for a variety
of applications
PyroSic and PyroKarb are fiber-reinforced
glass-ceramic composites based on
thermosetting inorganic polymers
They offer a lightweight thermal material,
cost-effectiveness and ease of fabrication

References (Links)
http://www.thomasnet.com/about/alloys-high-temperature-1190800.html
http://www.henkel-adhesives.com/aerospace/weight-reduction-news-26832-comp
osites-for-high-temperature-applications-47216.htm
http://www.fibermaterialsinc.com/category/thermo-composites/
http://
www.topgear.com/uk/photos/lambo-sesto-exclusive-2010-01-11?imageNo=10
http://www.motorsport-developments.co.uk/tech_articles/FAF264_tech.pdf