Processing, Characterization and Modelling of Interpenetrating Metal Ceramics Composites based on high-homogeneous foam structures

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The research project deals with the processing, characterization and modeling of interpenetrating composites (IPC) based on high-homogeneous ceramic foam preforms. The microstructural homogeneity of the preform used is decisive for the resulting composite properties in IPCs. With the innovative foaming process, which is derived from the manufacturing of high-temperature heat insulation and also applied in the context of this proposal, novel ceramic foams with a highly homogeneous microstructure and high fractions of open porosity can be produced in a process-safe and resource-efficient way for the first time. The foam preforms used in the project are provided by the company Morgan Advanced Materials Haldenwanger GmbH and feature different pore volume contents without the need of pore forming agents. Since such preforms produced by this patented process have not been used for the manufacturing of IPCs so far, the microstructure-property relationship is unknown. Furthermore, there are only few studies dealing with the behavior of penetration IPC under near-application loads, in particular with thermo-mechanical fatigue. By infiltrating the highly homogeneous alumina foam preform with an AlSi12 alloy, further lightweight construction potential, particularly in the area of thermally highly stressed components, e.g. for engine components, can be achieved. The research project has a holistic view on these novel IPCs. Hence, the planned investigations deal with the processing of the IPCs, including the process-accompanying analysis of the composite's constituents, the scientific characterization of the generated composites, as well as the modeling of these composites and the novel foam structures used. Near-application loads include mechanical, thermal and thermo-mechanical loading conditions. The damage behavior is to be analyzed and described in different load cases by in-situ and ex-situ investigations, in order to obtain a precise understanding of the damage mechanisms and the damage evolution in the composite. This is also to be made in a numerical model by means of suitable approaches. Based on the model, suitable fatigue-life models are derived and further developed. A further interesting aspect for later applications is the self-healing potential of these materials, which has not been investigated so far. For this reason, another aim of the project is the creation of a self-healing procedure of an interpenetrating composite after over-stresses.