Ceramic/aluminum co-continuous composite synthesized by reaction accelerated melt infiltration

A process to synthesize ceramic composites toughened by a three-dimensional interconnected network of ductile metal was investigated. It was found that when a porous ceramic preform, produced by general methods, is dipped into molten aluminum alloy at a temperature much higher than the alloy melting point, the molten aluminum alloy wets the surface of the preform and further infiltrates into the open interconnected porosity of the preform under the action of capillary. A ceramic/aluminum co-continuous composite can then be produced when the preform is cooled to room temperature. The chemical reaction between the ceramic preform surfaces and the molten aluminum alloy can accelerate infiltration. By this process, a kind of co-continuous ceramic composite, toughened by interconnected aluminum, was synthesized. An examination was carried out on the microstructure of the composite, the effects of alloying additions and the agents added into the ceramic preform, and the effect of temperature on the infiltration.