Low-cost Manufacturing of Bioinspired Damage-Tolerant Ceramic Composites

低成本制造仿生损伤耐受陶瓷复合材料

• 批准号: 2304846
• 负责人: Majid Minary-Jolandan
• 金额: $ 37.28万
• 依托单位: University of Texas at Dallas
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2022
• 资助国家: 美国
• 起止时间: 2022-10-01 至 2024-11-30
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=2304846&HistoricalAwards=false
• 关键词: Low; cost; Manufacturing; Bioinspired; Damage

Despite favorable properties of ceramic-metal composites, they have not been applied commercially to date, due in large part to processing cost and challenges. The conventional method for manufacturing lamellar ceramic-metal composites is melt-infiltration of the metal phase into the gaps of the ceramic scaffold. The smaller the gap, the more difficult the infiltration. Because of the poor wetting between most metals and ceramics, the process requires high pressure and temperature to squeeze the molten metal into the gaps in the ceramic phase. This project aims at developing manufacturing strategies inspired by nature to enable low-cost fabrication of ceramic-metal composites. Natural materials such as bone and the nacreous part of sea-shells have developed structural composites, using a set of rather ordinary constituents, which exhibit extraordinary mechanical properties. For example, seashells convert a brittle ceramic material to a super-tough material (nacre) by incorporation of around 5% polymer, in a layered ?brick-and-mortar? microstructure. The scientific community has been very successful in identifying the design principles of biological structural composites. However, manufacturing knowledge gaps persist. These include the challenge of infiltration of small gaps between ceramic bricks, the challenge of obtaining ductile (while strong) mortars; the challenge in design of proper (metal-ceramic) interfaces; and the high cost. Low-cost processes for fabrication of metal−ceramic composites can substantially increase their applications in various industries including automotive, aerospace, oil and defense, in products such as high performance wear-resistance parts, cutting tools, lightweight structural composites, and aero-engine components. For these reasons, the project directly impacts American economic welfare and national security. The educational objective of the project is focused on increasing the diversity in nanotechnology- STEM through ?NanoExplorer? summer program for high school students, with particular emphasis on female students, including Latinos. The goal of this research is to investigate the mechanisms underlying processing and manufacturing of ceramic composites for damage-tolerant structural applications. The project is focused on understanding infiltration of nanotwinned metals into nano-gaps (100 nm) of a 3-dimensional porous ceramic scaffold by pulsed electrodeposition. A conservative estimate shows that the energy consumption in this process is more than 200-fold smaller than the conventional molten metal infiltration process. The liquid electrolyte in electrodeposition has much less viscosity compared to molten metals, and hence can effectively penetrate into the small gaps between the ceramic bricks. A class of metals that defeat the trade-off between strength and toughness are ?nanotwinned? metals. Nanotwinned metals have high density of coherent twin boundaries, which has been shown to enhance both strength and ductility. Pulsed electrodeposition is one of the primary methods of synthesis of nanotwinned metals. To address the metal-ceramic interface challenge, electroless deposition of a thin metal layer on ceramic bricks is planned, which will result in uniform coating, as well as strong adhesion between ceramics and metals. This research, if successful, will result in new fundamental knowledge in following subjects: (i) Growth mechanism and microstructure of nanotwinned metals directly synthesized by pulsed electrodeposition into a laminated ceramic scaffold; (ii) Kinetics of pulsed electrodeposition process in nano-channels (100 nm); and (iii) Infiltration of a nano-porous ceramic scaffold by electrodeposition.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.

尽管陶瓷金属复合材料具有良好的特性，但迄今为止尚未商业应用它们，这在很大程度上是由于处理成本和挑战。制造层状陶瓷金属复合材料的常规方法是将金属相融化到陶瓷支架的间隙中。差距越小，渗透越困难。由于大多数金属和陶瓷之间的润湿效果不佳，因此该过程需要高压和温度才能将熔融金属挤压到陶瓷相中的间隙中。该项目旨在制定受自然启发的制造策略，以实现陶瓷金属复合材料的低成本制造。骨壳的天然材料（例如骨骼）使用了一组相当普通的成分，它们具有非凡的机械性能。例如，贝壳通过将约5％的聚合物掺入分层？微观结构。科学界在确定生物结构复合材料的设计原理方面非常成功。但是，制造知识差距持续存在。其中包括渗透陶瓷砖之间小缝隙的挑战，即获得延性（强大）迫击炮的挑战；适当（金属陶瓷）界面的设计挑战；和高昂的成本。用于制造金属陶瓷复合材料的低成本工艺可以大大提高其在各种行业中的应用，包括汽车，航空航天，石油和防御，例如高性能耐磨零件，切割工具，轻巧的结构复合材料，轻质结构复合材料，以及空气发动机的组件。由于这些原因，该项目直接影响美国的经济福利和国家安全。该项目的教育目标集中在通过纳米塑料来增加纳米技术的多样性？高中生的夏季课程，特别着重于包括拉丁裔在内的女学生。这项研究的目的是研究陶瓷复合材料的基础机制，用于耐损伤的结构应用。该项目的重点是理解纳米温金属通过脉冲电沉积的3维多孔陶瓷支架的纳米间隙（100 nm）的浸润。保守的估计表明，此过程中的能源消耗比传统的熔融金属浸润过程小200倍以上。与熔融金属相比，电沉积中的液体电解质的粘度要小得多，因此可以有效地渗透到陶瓷砖之间的小间隙中。一类打败力量与韧性之间权衡取舍的金属是否被纳米丝？金属。纳米温金属具有高密度的连贯双胞胎边界，已显示出可以增强强度和延展性的。脉冲电沉积是合成纳米金属金属的主要方法之一。为了应对金属陶瓷界面的挑战，计划在陶瓷砖上进行薄金属层的电子沉积，这将导致均匀的涂层，以及陶瓷和金属之间的牢固粘附。这项研究，如果成功的话，将为以下受试者提供新的基本知识：（i）直接通过脉冲电沉积直接合成的纳米温属金属的生长机制和微观结构为层压的陶瓷支架； （ii）纳米通道中脉冲电沉积过程的动力学（100 nm）； （iii）通过电沉积渗透纳米孔陶瓷支架。该奖项反映了NSF的法定任务，并且使用基金会的知识分子优点和更广泛的影响评估标准，被视为值得通过评估来提供支持。