Processing and properties of robocasted alumina-based ceramic matrix composites
MALIK R. 1, ZHOU S. 1, SAIZ GUTIERREZ E. 1
1 Imperial College London, London, United Kingdom
Additive manufacturing of fiber-reinforced ceramic matrix composites (CMCs) could revolutionize the engineering ceramic industry by tackling the long-standing challenges of high production cost and brittleness of ceramics. This study shows that complex-shaped alumina-based oxide CMCs with fiber (Nextel 610) content as high as 30 vol% could be fabricated using robocasting of a powder-based paste following gel infiltration and firing. The fiber lengths are above 0.5 mm. The mechanical response of the materials has been characterized using bending tests and related to their microstructure. Robocasting can be used to manipulate fiber alignment that will depend on the flow conditions, fiber length, and solid content of the paste. The composites exhibit gradual failure in bending while retaining strengths above 100 MPa. In situ mechanical testing is used to identify the toughening mechanisms. The newly developed materials have a high potential for intricate-shaped high-temperature structural components employed in the aerospace and nuclear industry.