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

互穿相复合材料（IPC）是复合材料的一个特殊子类别，其中每个材料相完全相互连接。这导致组分的连续体积结构。因此，复合材料由用第二不同基质材料渗透的开孔泡沫（预成型件）组成。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体的组合。由于IPC的特殊微观结构，这些复合材料与传统复合材料相比具有新的和增强的性能，如在高温水平下更高的抗蠕变性。由于目前使用的渗透工艺，IPC不能获得其全部潜力，因为在渗透过程中发生的损坏。成形过程中的高温和高压会导致结构性能不足，例如预制件断裂、复合相之间分离或残余孔隙。这影响低机械性能，例如低强度，或甚至复合材料的结构完整性不足。由于半固态成形工艺具有较低的加工温度和较低的机械压力，因此半固态成形技术可以满足金属陶瓷IPC的生产要求。因此，本研究计画将以半固态成形制程制造金属陶瓷IPC为研究重点。因此，渗透过程的确切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。本研究项目的科学任务是开发一种新的金属-陶瓷IPC的制造工艺，并更好地理解半固态金属合金渗透陶瓷体积结构过程中发生的机制。

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.