Manufacturing of metal-ceramic Interpenetrating Phase Composites using semi-solid forming

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Interpenetrating Phase Composites (IPC) are a special subcategory of composites in which each material phase is completely interconnected. This results in a continuous volume struc-ture of the components. Thereby, the composite consists of an open-cell foam (preform), which is infiltrated with a second different matrix material. In this context, the most frequently used composite class is the combination of a ceramic preform with a metallic matrix. Be-cause of the special microstructure of IPC, those composites have new and enhanced prop-erties compared to conventional composite materials like higher creep resistance at high temperature levels. Due to the current infiltration processes used, IPC are not able to gain their complete potential because of damages occurring during the infiltration processes. High temperature and pressure during forming process cause insufficient structural properties such as a broken preform, separation between the composite phases or residual porosity. This affects low mechanical properties, such as low strength, or even an insufficient structural integrity of the composite. Processing such composites using the semi-solid forming tech-nology offers great perspectives with regard to the requirements demanded for the production of metal-ceramic IPC because of the relative low processing temperatures and reduced mechanical pressures during this forming process. For this reason, proposed research project will focus on the manufacturing of metal ceramic IPC by means of the semi-solid forming process. Thus, the exact parameters of the infiltration process will be specified by means of forming trials and by numerical modelling. The achieved results will be evaluated by analysing structural, mechanical and thermophysical properties. The scientific task of this research project is the development of a new manufac-turing process for the metal-ceramic IPC and the obtainment of a better understanding of the mechanisms occurring during the infiltration of ceramic volume structures by a semi-solid metal alloy.