Low-Cost Manufacturing of Metal–Ceramic Composites through Electrodeposition of Metal into Ceramic Scaffold

Abstract

Infiltration of a molten metal phase into a ceramic scaffold to manufacture metal−ceramic composites often involves high temperature, high pressure, and expensive processes. Low-cost processes for fabrication of metal−ceramic composites can substantially increase their applications in various industries. In this article, electroplating (electrodeposition) as a lowcost, room-temperature process is demonstrated for infiltration of metal (copper) into a lamellar ceramic (alumina) scaffold. Estimation shows that this is a low energy consumption process. Characterization of mechanical properties showed that metal infiltration enhanced the flexural modulus and strength by more than 50% and 140%, respectively, compared to the pure lamellar ceramic. More importantly, metal infiltration remarkably enhanced the crack initiation and crack growth resistance by more than 230% and 510% compared to the lamellar ceramic. The electrodeposition process for development of metal−ceramic composites can be extended to other metals and alloys that can be electrochemically deposited, as a low-cost and versatile process.

Bioinspired alumina/reduced graphene oxide fibrous monolithic ceramic and its fracture responses

“…To describe the evolution of the crack extension length and crack growth resistance during crack propagation, the crack growth resistance curve (R‐curve) is usually calculated from a J‐integral by accounting for the local deflection and other dissipation mechanisms. This approach reflects the relationship between the fracture growth toughness ( K JC ) and crack extension length (Δ a ) extracted from the load‐displacement curves . Details on the R‐curve calculation are explained below.…”

“…This approach reflects the relationship between the fracture growth toughness (K JC ) and crack extension length (Δa) extracted from the load-displacement curves. 30,31 Details on the R-curve calculation are explained below.…”

Designing bioinspired brick-and-mortar composites using machine learning and statistical learning

“…Clearly, a much more detailed study is needed to understand trade-offs between all other design possibilities, other mechanical properties of brick-and-mortar, or mechanical behavior under different loading conditions. The presented RVE draws inspiration from previous analytical and numerical studies for the micromechanical modeling of composite materials 29,37,[48][49][50] . For reference, the FEA model predictions are compared to the measured properties of the nacre-inspired synthetic Al 2 O 3 /PMMA (poly(methyl methacrylate)) composite 28 , and an analytical model presented in ref.…”

“…1. This architecture is inspired by natural materials, and there have been many studies in the literature aiming at manufacturing such composites [28][29][30][31][32] . Natural materials such as nacreous part of sea shells have developed structural composites, using a set of rather ordinary constituents, which exhibit extraordinary mechanical properties.…”

“…Additionally, materials properties of the brick and mortar should be also added to this list. Such a large design space cannot be fully examined by experimental work since manufacturing processes for such composites are often costly 28,29 .…”