Ceramic matrix- and layer-composites in advanced automobile technology

Bulk ceramic materials for structural and functional applications have been in the center of interest in R&D and product development of various industries since many years. Even if the technical requirements could be achieved the cost/performance ratio was unsatisfying in many cases. Recent product development in light weight design and engineering offers a lot of interesting manufacturing and operation features if cost effective composite solutions including ceramic components can be realized. Advanced light metal engineering and ceramics must not be competitors or contrary but in an appropriate combination they can excel in production cost, functionality, performance and energy consumption. Ceramic matrix composites with carbon fiber reinforcement can fulfill these requirements for high temperature, structural and friction applications and the same is true if light metal substrates can be combined with performing ceramic, cermet, metallurgical or polymer based surface layers for various machine elements and system components. Protective and functional coatings on light metal surfaces can be individually designed. The paper describes manufacturing technologies as well as materials and components characterization results, e. g. high temperature resistant friction materials made from SiC based CMC as well as coating technologies for the deposition of ceramic, metallurgical and preceramic polymer coatings on various light metal substrates. The specific characteristics and advantages of these composites are presented for advanced disk brake technology and full light metal motor engineering with a focus on ceramic coated crankcases and cylinder surfaces of combustion engines. In addition, tribologically optimized combined coatings on light metal components are introduced. Their tailored surface properties can compete with bulk ceramics and feature with additional characteristics like antiadhesive and dry lubricant ability.