Insights into morphology and mechanical properties of architected interpenetrating aluminum-alumina composites

Additive manufacturing (AM) technologies are unleashing the restrictions imposed by conventional manufacturing, allowing the production of innovative designs tailored to improve properties or performance. AM techniques in ceramic production allow the application of novel designs to ceramic parts, opening new opportunities for combining technologies aiming to obtain architected interpenetrating phase composites (IPCs). In this study, alumina structures with different architectures and Computer Aided Design (CAD) structure porosity oriented unidirectionally or bidirectionally, were fabricated by vat photopolymerization technique, namely Digital Light Processing. Afterwards, these structures were infiltrated with an aluminum alloy through investment casting, thus obtaining aluminum-alumina IPCs. Under compression, the IPCs presented a ductile behavior, conversely to the fragile ceramic counterparts. The IPCs compressive strength and absorbed energy were expressively higher than their ceramic counterparts. Comparing the bidirectional IPCs with the unidirectional ones, a significant increase in compressive strength and absorbed energy was observed, from 36.2% to 42.3% and from 164.8% to 358.1%, respectively, due to the greater amount and interconnection of the metal inside the ceramic structure. This study demonstrates the feasibility of this manufacturing route, combining two distinctive technologies, for the fabrication of metal-ceramic architected IPCs, allowing to tailor their mechanical properties and energy absorption capacity for a given application. Graphical Abstract