Electrification of thermal processes

Electrically conductive ceramic materials far exceed the capabilities of established metallic heating conductor alloys. In conventional heating processes from room temperature to 1000 °C, they offer greater reliability, durability, energy efficiency, and compactness. In addition, the variability and combination of properties enable innovative heating solutions for demanding tasks: temperatures above 2000 °C, high power density, rapid heating and cooling, high oxidation loads, chemically corrosive atmospheres, or mechanical stresses. Thanks to the diverse properties of different ceramic materials, the electrical connection parameters can be designed to be variable and process-oriented. This allows heating processes to be implemented that were previously only possible using gas combustion.

In addition to traditional ceramic heating elements made of silicon carbide (SiC), Fraunhofer IKTS provides a broad material base for heating conductor concepts. Special SiC material types (R-SiC, S-SiC, LPS-SiC, Si-SiC) can be adapted to desired electrical parameters and combine these with the advantages of SiC. Other materials such as TiO₂, ZrO₂, ZrC, B₄C, or composites with Si₃N₄, AlN, or BN + TiC, TiB₂, or MoSi₂ meet application requirements such as temperature, corrosion and oxidation stability, mechanical strength, stiffness, and vacuum resistance better than conventional heating conductor materials. In addition to sintered ceramic materials, glasses, powder fillings, or refractory materials can also be integrated into the heating concepts to create the optimal heating solution. The important electrical contacting is also part of the system integration work.

Examples for application / references 
 

• Linear evaporator elements made of S-SiC with dual function
• Heating elements made of zirconium carbide up to 2400 °C
• Titanium oxide heating elements for oxidizing atmospheres up to 1600 °C
• Composite heating elements with a wide range of properties
• Powder heating elements
• Glass heating elements
• Refractory heating elements

Services offered
 

• Consulting on the selection of modern ceramic materials for customer-specific heating processes
• Development of new ceramic heating elements for customer-specific applications
• Testing and characterization of the heating behavior of heating conductor materials and heating elements
• Development of multifunctional heating elements (e.g., heater + sensor + catalyst)
• Simulation and optimization of the thermal management of heating systems
• Development and testing of electrical contacts

Technical equipment
 

• Test stand for application-related tests of heating conductors up to 1600 °C in air
• Test stand for heating conductor materials up to 2200 °C under vacuum
• Measurement of electrical resistance up to 1400 °C in argon, nitrogen, or air
• Pilot line for the production of heating conductor components and parts