Ceramics in the car—key technology for efficiency and emission control
Technical ceramics are indispensable in automotive engineering. In conventional combustion engines, spark plugs and ceramic glow plugs ensure reliable ignition and long-lasting performance—even at extreme temperatures. Highly insulating ceramic connectors and components ensure the operation of electronic systems under the hood. Lambda and particulate matter sensors use ceramic elements for accurate exhaust gas monitoring. In catalytic converters, ceramic carrier structures ensure effective exhaust gas purification.
Ceramics are also playing a growing role in electric mobility, for example, in battery systems, lightweight, temperature-stable housings, or high-performance sensors. Their resistance to heat, chemicals and mechanical stress makes them a versatile material in mobility, both now and in the future. New developments are further advancing efficiency, safety and sustainability throughout the vehicle.
Ceramic materials in automotive engineering: invisible performance drivers for efficiency, emission reduction and electric mobility
Technical ceramics have played an important role in the automotive industry for decades—often hidden away, but with a decisive influence on efficiency, safety and environmental compatibility. From conventional applications in combustion engines to key components for modern exhaust gas aftertreatment and electric mobility, ceramic materials are making a significant contribution to the further development of current and future vehicle technologies.
Among the best-known applications are spark plugs for gasoline engines and glow plugs for diesel engines. Aluminum oxide ceramic provides electrical insulation and temperature resistance in extremely stressed components. Thanks to their fast response time, modern ceramic glow plugs enable efficient and clean combustion—even at low temperatures and with short starting cycles. Ceramics are also indispensable in exhaust gas measurement technology: Lambda sensors used to regulate the air-fuel mixture, as well as particulate matter sensors or NOx sensors are based on functional ceramic materials such as zirconium oxide or spinel structures. These sensors provide accurate data at high temperatures and in corrosive exhaust gases—a prerequisite for compliance with current emission limits.
Another key area is exhaust gas aftertreatment. In catalytic converters, ceramic monolith carriers—usually made of cordierite or aluminum oxide—assume the role of high-temperature-resistant, porous substrates onto which the catalytically active precious metals are applied. In diesel particulate filters (DPF) or SCR systems to reduce nitrogen oxides, ceramic materials are used as filter media or structural bodies, which impress with their precise pore structure and high thermal shock resistance.
Ceramic applications are becoming more important with the increasing electrification of the drivetrain. Connector housings, insulators, high-voltage bushings and substrates for power electronics have to withstand voltages of up to 800 volts, be thermally stable and electrically insulating. Materials such as aluminum oxide, aluminum nitride (AlN) or silicon nitride are used here—in some cases also as carriers in active modules, for example, in DC/DC converters, inverters or onboard charging systems. PTC ceramics can also be used in the heating systems of electric vehicles, since there is no longer any waste heat from the engine to heat the interior.
In addition, ceramic components improve the energy efficiency and service life of modern vehicles, for example, as bearing materials in pumps and turbochargers, plain bearings in electric motors, friction elements in clutches, or sensor carriers in battery management systems. Their wear resistance, low thermal expansion and chemical resistance enable safe and long-term stable use in highly stressed components.
Ceramic materials for hydrogen vehicles are an exciting trend, for example, as electrolytes in fuel cells or as membranes and sealing systems in hydrogen tanks and pipes. Here too, chemical stability, tightness and temperature resistance are key requirements that only ceramic materials can meet.
Future developments will focus on miniaturized, multifunctional ceramics, additively manufactured components for functional integration and intelligent sensor components to monitor vehicles. In the context of increasing system complexity and sustainability requirements, the demands on materials are growing—and with them the potential of ceramic solutions. Whether in conventional drive systems, hybrid vehicles or all-electric mobility concepts, ceramics are proving to be indispensable high-tech components for the automotive future.