Project description

The most important aim of this subproject is the fabrication and coating of ceramic polymer and ceramic metal composite materials with improved mechanical strength and toughness and ultra-high packing density by using the spouted fluidized bed spray granulation process in a novel miniaturized plant. The fabricated granules are assembled afterwards to bulk materials by hot pressing and final mechanical properties are characterized. The fabricated composites consist of a hard disperse phase (ceramic, metal) and a soft continuous phase (high performance polymer). The envisaged structure of composites is hierarchically designed. The pre-structured granules are supplied from projects A1, A2, and A6. A multiscale simulation strategy including the discrete element modeling (DEM) for determination of mechanical properties and microstructure of the produced composite materials is applied, where two hierarchical levels will be modeled. The additional coupling with CFD simulations of the fluid phase will allow optimizing and analyzing the influence of the process parameters on the particle formulation and the transport processes. Main material parameters are composition, shape and size of the particles as well as type of polymer.

A further extensive part of the subproject is, in cooperation with subproject C5, to simulate sintering and thermal expansion of thermal barrier coatings occurring in photonic structures using DEM. The DEM allows to predict the influence of different conditions on the material behavior as well as to consider influence of the material microstructure. The research in this area is focused on optimization of the geometric and structural parameters of photonic structures to avoid material collapse, such as debonding and crack formation. In order to validate simulation results experimental data are obtained in subproject C5 is used.

Project leaders
Prof. Dr.-Ing. habil. Dr. h.c.
Stefan Heinrich,
Asst.-Prof. Dr.-Ing.
Maksym Dosta,

fluidized bed




multiscale simulation

thermal expansion                                        sintering


1. M.F.H. Wolff et al.: Novel, highly-filled ceramic-polymer composites synthesized by a spouted bed spray granulation process. Composites Sci. & Technol. 90, 154, 2014 - with A6

2. E. Eichner et al.: Using dilute spouting for fabrication of highly filled metal-polymer composite materials. Powder Technol. DOI:10.1016/j.powtec.2016.12.028, 2017 - with A6

3. R. Besler et al.: Sintering simulation of periodic macroporous alumina. J. Am. Ceram. Soc. 98, 3496-3502, 2015 - with C5

... and more on the list of publications.

open as PDF.