IRCER Imerys joint laboratory – LIRYS

As part of this collaboration and joint strategy, it is expected that the TRL will be raised thanks to Imerys Aluminates' expertise and capabilities in various oxide ceramic powder synthesis processes, such as supercritical fluid synthesis and melting processes (electric arc melting, induction melting). These synthesis processes, as well as powder processing (grinding, classification, atomisation, heat treatment, etc.), are Imerys' core business and are widely used within the group, from laboratory scale to industrial scale, including pilot phases. For its part, IrCer contributes its expertise in various ceramic deposition processes such as APS (Air Plasma Spraying) and SPS (Suspension Plasma Spraying), as well as its knowledge of the phenomena involved in deposition with a view to optimising raw materials and deposition parameters.
The areas of development chosen to initiate this collaboration concern:
- Area 1: Coatings for gas turbines for energy production with thermal barriers.
- Area 2: Coatings for ceramic firing supports for applications in electronics and lithium-ion batteries, in order to create protective layers for the calcination of reactive powders and the sintering of high added-value ceramic parts.
This joint strategy aims to improve the durability of systems and thermal efficiency and, thanks to a French player in the synthesis of ceramic powders, to achieve national sovereignty in the production of raw materials for the creation of ceramic deposits in strategic areas.

The LYRIS laboratory will focus on two areas: thermal barriers (area 1) and thermal coatings for baking trays (area 2).
Area 1: Thermal barriers are a priority area of development within LIRYS. The joint laboratory is committed to improving the properties of thermal barriers and developing a robust approach covering everything from input production to coating application and characterisation of its properties. This will be achieved through work on powder using two significant innovations: morphological and chemical.
Climate change, caused by the release of greenhouse gases from human activities such as the burning of fossil fuels, is having a significant impact on the planet and is becoming an increasingly important concern for society. Improving thermal barriers could help reduce the environmental impact of electricity generation by optimising the land-based turbines used to convert fuel into electricity.
Imerys is already present in this market through the supply of powders to its customers. Research in this area will enable the company to increase its sales volumes and reduce its ecological impact.
Area 2: This involves developing ceramic firing support coatings that are resistant to high-temperature thermal cycling and compatible with sintered materials or calcined powders.
Firing supports are used in many applications. Currently, suppliers and users of firing supports either produce solid parts or use ceramic powders that are placed between the support and the part to be sintered. These systems have a limited lifespan (approximately 50 to 100 cycles).
The target markets for the joint laboratory are high value-added applications such as electronics (MLCC, ferrites and piezoelectric materials) and the energy market (calcination of powders for battery materials and materials for fuel cells).

The industrial research issue being addressed by Imerys Aluminates and IrCer is ambitious and has many ramifications. As outlined in the roadmap, the work initiated with ANR funding is set to continue for many years: on the one hand, the results obtained will need to be pursued at a higher level (up to TRL 8-9); on the other hand, the testing methods developed and the scientific skills and knowledge acquired are intended to be exploited and leveraged beyond the duration of the funding.

In process

As part of the LIRYS labcom, IrCer laboratory and Imerys Aluminates will mutualize their expertise in the field of thermal spray applications and the synthesis of ceramic powders in order to develop innovative and sustainable solutions for the manufacture of ceramic thin coatings for high end applications.

In the spirit of this collaboration and a common strategy, it is expected to facilitate the rise in TRL (technology readiness level) thanks to the know-how and capabilities of Imerys Aluminates on various processes for the synthesis of ceramic oxide powders such as supercritical water synthesis or fusion processes (electric arc fusion, induction fusion). These synthesis processes but also the elaboration of powders (grinding, classification, spray drying, thermal treatment, etc.) are Imerys' core business and are widely used within the group from lab to industrial scales.

For its part, IrCer will bring its expertise in the realization of ceramic coatings by APS (Air Plasma Spraying) or SPS (Suspension Plasma Spraying) as well as its knowledge in understanding phenomena related to production of these deposits in order to optimize the raw materials properties or the spray parameters.

The areas of development chosen to initiate this collaboration concern two main axes :

- Axis 1: Thermal barrier coatings for gas turbines in relation to energy production.

- Axis 2: Ceramic coatings for kiln furniture applications in electronics or batteries (e.g. Li-Ion) in order to produce protective layers either for the calcination of reactive powders or to avoid reaction between the kiln furniture and the ceramic parts during the sintering process for high added value applications. The common objective being to improve the life cycle (thermal performance and chemical stability).

In this common strategy, it is considered to improve the durability of the systems and the thermal efficiency. Thanks to a French player in the production of ceramic powders. It is also aimed to have national sovereignty in the production of the raw materials for the realization of ceramic deposits in strategic markets.