Design and manufacture of near-net-shape metal-ceramic composites with gradient-layered structure and optimized damage tolerance

Optimizing the composition and structure of materials in localized regions of the materials is an effective approach to enhance the material utilization efficiency and achieve a performance-on-demand design. However, it is challenging to achieve such design owing to limitations in manufacturing technology . In this study, we devised a method involving vat photopolymerization 3D printing and magnet-assisted pressure infiltration techniques for fabricating near-net-shape customized gradient composites with Al/Al 2 O 3 as the model system. The mechanical properties of the fabricated Al/Al 2 O 3 composites at specific locations could be optimized by appropriately setting the thickness ratio of the metal layer to the ceramic layer , and a desirable combination of strength , toughness, and wear resistance could thereby be achieved. The fracture behavior of the composites was analyzed through in situ observation and finite element simulations . The proposed design concept and fabrication method are flexible and adaptable, and they can be easily extended to other material systems and structural models. They are expected to pave the way for the development of lightweight, strong, tough, and near-net-shape structural and functional materials .