Structural Heat-Resistant Composites and Fire Barriers

Advanced glass-ceramic matrix composites with user-friendly processing

PyroSic

Exhaust duct made out of PyroSic

After 10 years of development, Pyromeral Systems has introduced an entirely new generation of materials that finally brings the advantages of composites to the world of high temperatures. With this technology, it is now possible to design and manufacture lightweight composite parts used at high temperatures that not only provide an excellent level of thermo-mechanical performance, but also remain easy and affordable to produce.

These new composite materials, marketed under the PyroSic® and PyroKarb names, are based on proprietary glass-ceramic matrix systems reinforced with silicon carbide or carbon fibers. Thanks to the use of advanced inorganic polymers, they are processed at low temperatures with the same techniques and tooling as those used for conventional carbon-fiber reinforced plastics (CFRP). Yet, they also offer a much improved resistance to heat and fire, as they retain good mechanical properties at temperatures for which CFRP cannot even be considered (typically, up to 1000°C/1800°F).

Compared to conventional ceramic matrix composites (CMC), PyroSic or PyroKarb do not use complex processes like chemical vapor infiltration (CVI), iterative densification, polymer infiltration and pyrolysis (PIP) or hot isostatic pressing. As a consequence, they greatly improve the producibility of lightweight composite parts designed for heat and fire exposure. They enable substantial reduction in tooling cost, as conventional tooling materials can be used for their processing. They also make possible the production of prototypes with short lead times, as well as the design and production of large or complex parts.

Typical properties of our structural composites include:

  • Lightweight, especially compared to metals like steel, inconel or titanium,
  • Resistance to long term exposure up to 1000°C (1800°F) depending on the reinforcement. Short-term exposure at higher temperatures is possible,
  • Fire-resistance, incombustibibility and absence of smoke when exposed to heat or fire,
  • Retention of good mechanical properties at high temperatures,
  • Compatibility with applications requiring good mechanical strength and resistance to vibrations,
  • Dimensional stability at high temperatures,
  • Compatibility with hybrid designs (e.g. organic/inorganic combinations), insulating inserts or coatings,
  • Convenient processing at low temperatures (< 150°C/300°F) with CFRP techniques including lay-up material, filament winding, compression, pultrusion or tape placement,
  • Compatibility with large or complex shapes,
  • Affordable and quick to implement with minimal R&D work.
PyroSic hybrid with carbon epoxy composites and metalic heat shield

Hybrid composite material: Carbon epoxy (1)
and PyroSic (2) covered with a reflective coating (3)

Applications for PyroSic and PyroKarb include heat shields, exhaust ducts, pipes for hot fluids or gases, fire barriers and other structural components. The materials are typically used in the field of motorsports, aerospace, defense, naval or automotive, either as a replacement of metals for weight reduction purposes, or as a replacement/complement for CFRP for improved thermal stability.

With our expertise in the manufacturing of parts made of high temperature composites, we are well positioned to help our customers complete quickly and effectively their projects. Please, contact us to find out how, together, we can work on your solution.