Co-sintering of metal-ceramic composites with three-dimensional complex structures

金属-陶瓷复合材料提供了高的灵活性和巨大的技术应用潜力，因为它们提供了扩展性能谱和联合收割机不同性能如局部导电性和绝缘能力的可能性。更实际的是，陶瓷的脆性特性可以通过分级或组合不同的韧性金属成分来积极影响，以实现高硬度、韧性和损伤容限。尽管有这些优点，但这种复合材料到目前为止主要是通过流延组合不同的箔来生产的。大批量生产复杂结构的部件仍然具有挑战性。在本项目中，将采用熔融纤维制造（FFF）工艺进行复杂复合材料的增材制造，并对其进行系统研究以应对挑战。该项目的主要目标是了解变形，内部应力的演变和损伤，由于分层的任意三维形状的金属-陶瓷复合材料部件在共烧结过程中，并制定一个可靠的数值方法来预测和优化的应力状态在复合材料已经在设计阶段。烧结过程中的变形和分层应该能够通过降低复合材料中的临界剪切应力和拉伸应力来避免。通过开发的数值方法，一方面，可以直接对部件设计进行特定于材料和工艺的优化，以避免生产过程中出现意外缺陷。另一方面，FFF工艺有望实现具有集成智能的复杂形状部件的生产，例如，金属部件可以设置有用于磨损保护的陶瓷涂层。

Metal-ceramic composites offer high flexibility and great potential for technical applications due to the possibility they offer to extend the property spectrum and to combine divergent properties such as local electrical conductivity and insulating capability. More practically, the brittle characteristics of ceramics can be positively influenced by grading or combining different ductile metal components to achieve high hardness, toughness and damage tolerance. Despite these benefits, such composites are until now mainly produced by combining different foils by means of tape casting. The production of components with complex structures in large volume is still challenging. In this project, the additive manufacturing of the complex composites using the Fused Filament Fabrication (FFF) process will be carried out and systematically studied to face the challenge. The main objectives of the project are to understand the deformation, internal stress evolution and damage due to delamination in metal-ceramic composite components of arbitrary three-dimensional shape during the co-sintering process and to develop a reliable numerical method to predict and optimize the stress state in the composite already in the design phase. Distortion and delamination during sintering should be able to be avoided by reducing the critical shear and tensile stresses in the composite. With the developed numerical method, on the one hand, material- and process-specific optimization of the component design can be performed directly to avoid unexpected defects during production. On the other hand, the FFF process is expected to enable the production of complex shaped components with integrated intelligence, e.g., metallic components can be provided with a ceramic coating for wear protection.