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

互穿相复合材料是复合材料的一个特殊子类，其中的每一种材料相是完全相互关联的。这导致部件的连续体积结构。因此，该复合材料由开孔泡沫(预制件)组成，该开孔泡沫(预制件)渗透有第二不同的基质材料。在这种情况下，最常用的复合材料类别是陶瓷预制件与金属基质的组合。由于IPC特殊的微观结构，与传统复合材料相比，这些复合材料具有更高的高温蠕变抗力等新的和增强的性能。由于目前使用的渗透工艺，由于渗透过程中发生的损害，IPC无法充分发挥其潜力。成型过程中的高温和压力会导致预制件断裂、复合材料相分离或残余气孔等组织性能不足。这会影响低机械性能，如低强度，甚至复合材料的结构完整性不足。利用半固态成形技术加工这种复合材料，由于成形过程中的加工温度相对较低，机械压力较小，因此对生产金属陶瓷IPC的要求具有很大的发展前景。为此，提出的研究项目将集中在利用半固态成形工艺制造金属陶瓷IPC。因此，渗透过程的准确参数将通过成形试验和数值模拟来确定。将通过分析结构、机械和热物理性能来评估所取得的结果。这一研究项目的科学任务是开发一种新的金属陶瓷IPC制造工艺，并更好地了解半固态金属合金渗透陶瓷体积结构时的机理。

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.