Microstructural, thermophysical and mechanical characterisation of Ceramic Matrix Composites (CMCs) developed in the HORIZON 2020 CEM-WAVE project

The presented PhD research is part of the HORIZON2020 project CEM-WAVE and investigates the microstructural, thermophysical, and mechanical properties of Ceramic Matrix Composites (CMCs), advanced materials that offering outstanding mechanical strength, thermal stability, and corrosion resistance. These features make CMCs highly suitable for a wide range of applications. However, their widespread adoption is hindered by high costs, complex manufacturing processes, lack of standardization, and difficulties in repair and scalability. CEM-WAVE aims to overcome these limitations by developing more efficient and sustainable manufacturing technologies, such as the MW-CVI process (Microwave-assisted Chemical Vapour Infiltration), with the goal of reducing the environmental impact of energy-intensive industrial sectors (Hard-to-Abate). This research focuses on the application of CMCs as radiant tubes in furnaces for steel production, in collaboration with the end-user ArcelorMittal. These components are expected to operate at high temperatures (up to 1200 °C), exceeding the current limits of superalloys and stainless steels. Experimental campaigns were carried out on composite materials (SiCf/SiC and Al₂O₃f/Al₂O₃-ZrO₂), including mechanical and thermophysical testing, as well as microstructural analysis before and after testing. These efforts were followed by preliminary modelling to assess the feasibility and thermal efficiency improvements offered by the proposed CMC solutions.