Silicon‑carbide fibre‑reinforced SiC matrix (SiCf/SiC) ceramics are regarded as key enabling materials for combustor liners, flame tubes and protective sleeves operated beyond 1 300 °C, yet fabrication of large tubular components remains constrained by the poor weaveability of brittle SiC rovings. The ZIM consortium project RoSiC therefore focused on transferring SiC fibres into 3‑dimensional multilayer fabrics that can be filament‑wound into near‑net‑shape preforms and subsequently chemical‑vapour‑infiltrated (CVI) to full ceramic composites. Central scientific challenges addressed were (i) fibre sizing, (ii) loom adaptation, (iii) 3‑D weave design, and (iv) scale‑up of the winding/CVI route to large‑scale SiCf/SiC‑Composite pipe geometries [1].

 A factorial workflow combined tribological characterisation of several candidate sizings with weaveability trials on a modified Dornier rapier loom. The most promising finish—a thin olefinic film (Dakolub)—reduced filament–guide friction by >40 % and permitted web speeds up to 50 m min⁻¹ without filament fracture [2].

Loom modifications comprised a tangential 972‑position creel, low‑abrasion ceramic eyelets and customised grippers, ensuring undulation‑free warp delivery of 3 × 7 K SiC rovings while maintaining textile integrity 

On this platform a 3‑D angle‑interlock layer‑to‑layer architecture was selected after comparing four bindings with areal densities between 630 and 1 040 g m⁻²; the chosen design exhibited the lowest pore volume and highest green density after CVI screening.

Eight‑ply fabrics (≈ 75 cm width) were filament‑wound around aluminium mandrels (Ø 155 mm / 130 mm), consolidated in a hot‑roll press and pyrolysed to C/C status. CVI processing (Si + C₂H₂, 1 300 °C, 200 h) added 1.8 – 2.3 kg SiC per tube 

Microscopy on cross‑sections confirmed uniform matrix penetration and damage‑free yarn cross‑overs through the 3‑D interlocks. Mechanical characterisation on curved ring specimens yielded flexural strengths of 149 MPa (Ø 155 mm) and 103 MPa (Ø 130 mm) at 1.9 g cm⁻³ density with quasiductile failure strains up to 0.72 % —values that already approach aero‑engine CMC benchmarks while offering ~25 % weight reduction over monolithic Si‑SiC. Comparative trials with 3‑layer carbon fabrics infiltrated to C/C‑SiC validated the scalability of the textile route and highlighted the critical role of balanced warp/weft yarn tension during winding to suppress multi‑layer wrinkling.

The work demonstrates, for the first time, a continuous process chain for large (> 750 mm length) SiCf/SiC tubes based entirely on industrial weaving and winding equipment. The success is rooted in three innovations: (1) an ablative olefin finish that temporarily stiffens SiC rovings yet sublimes cleanly during pyrolysis; (2) a tangential creel and positive‑grip shuttle system that cut contact stresses below the SiC filament fracture threshold; and (3) a 3‑D multilayer weave that couples in‑plane hoop strength with through‑thickness crack bridging, thereby delaying catastrophic leakage—an effect consistent with earlier observations on 3‑D woven SiCf/SiC at 1 480 °C [2].

Moreover, the measured flexural performance aligns with micromechanical damage models for orthogonal 3‑D SiCf/SiC composites [3] and confirms that the CVI parameters chosen here achieve matrix continuity comparable to aerospace‑grade reference systems [4]. The approach thus closes the gap between laboratory hand‑lay‑up trials and serial production envisioned for next‑generation hydrogen combustors and concentrated solar receiver tubes. Future work will address automated deposition of the olefin finish and real‑gas cyclic testing above 1 400 °C to validate long‑term creep models [5].

RoSiC establishes a robust, scalable textile platform for manufacturing 3‑D multilayer SiCf/SiC composite pipes with demonstrable high‑temperature capability. By uniting fibre chemistry, loom engineering and process modelling, the consortium delivered a technology package that significantly broadens the design envelope for tubular CMC components in energy and propulsion systems.

 In summary, the RoSiC programme has conclusively demonstrated that the long‑standing hurdles to producing large, tubular SiCf/SiC components can be overcome by an integrated, textile‑to‑CVI process route. The combination of a sacrificial olefin sizing, a positively driven rapier loom modified for fragile ceramic filaments, and a 3‑D multilayer angle‑interlock architecture has delivered defect‑free preforms that translate—after filament winding and SiC CVI—into pipes with mechanical properties already approaching aerospace standards. Beyond the technical metrics, the project establishes an industrially scalable pathway that is compatible with existing weaving and winding infrastructures, thereby minimising capital barriers for adoption. The resulting lightweight, oxidation‑proof tubes are poised to enhance efficiency, durability and safety in hydrogen combustors, concentrated‑solar receivers and other high‑temperature energy systems, while simultaneously reducing maintenance cycles and life‑cycle costs. Taken together, the work elevates SiCf/SiC composites from laboratory curiosities to manufacturable solutions and positions the consortium—and by extension European industry—as a frontrunner in next‑generation ceramic‑matrix composite technology.