Preparation Methods and Research Progress of Ceramic Particle Reinforced Metal Matrix Wear-Resistant Composite Materials

Ceramic particle-reinforced metal matrix wear-resistant composite materials combine high-hardness ceramic particles with metal materials. They combine the high hardness and wear resistance of ceramic particles with the toughness of the metal matrix material. A ceramic-metal composite layer with a certain thickness is formed on the working surface of the wear-resistant component.

The composite layer bears the wear, while the metal matrix provides the load-bearing function. This composite method not only improves the wear resistance of the wear-resistant component but also ensures its overall toughness. It has advantages such as high strength, high rigidity, low density, high temperature performance, and good wear resistance and corrosion resistance. It is widely used in aerospace, aviation, mining, and construction machinery manufacturing industries.

Manufacturing Method

Powder Metallurgy Method

The powder metallurgy method is one of the common methods for preparing ceramic particle-reinforced metal matrix composite materials. In this method, metal powder and ceramic powder are uniformly mixed and then sintered at high temperatures to form a composite of the metal matrix and ceramic particles.

Melting Mixing Method

The melting mixing method involves mixing metal and ceramic materials and then melting them at high temperatures. The mixture is subsequently cooled to form the ceramic particle-reinforced metal matrix composite material. This method can produce composites with high density and strength, but it may encounter issues with uneven particle distribution.

Deposition Method

The deposition method involves uniformly dispersing ceramic particles in an electrolyte and immersing the metal matrix in the electrolyte. A layer of ceramic particles is then deposited on the surface of the metal matrix, forming a composite material. This method ensures uniform particle distribution but has certain limitations on particle size and shape.

Process Requirements

Material Selection

The choice of ceramic particles has a significant impact on the properties of the composite material. Currently, commonly used ceramic particles include silicon carbide, alumina, zirconia, and other materials. With the continuous development of new materials, such as alumina-reinforced titanium diboride and silicon carbide-reinforced aluminum-based composites, more excellent ceramic materials will be applied to ceramic particle-reinforced metal matrix composites.

Interface Design

Due to the differences in physical properties, such as thermal expansion coefficients, between the metal matrix and ceramic particles, issues such as stress concentration, delamination, and debonding may arise. Therefore, interface design is an important means to address material adhesion issues. Current methods include increasing the interface layer between the metal matrix and ceramic particles and using interface binders.

Preparation Process

The preparation process is a crucial factor affecting ceramic particle-reinforced metal matrix composite materials. Current research focuses on factors such as preparation temperature, holding time, and pressure. With the continuous development of preparation technology, new methods such as ultrasonic vibration and plasma spraying will be applied in this field.

Our company has conducted research and development trials on this material. We use the casting infiltration method for material preparation. The main challenge of the production process is the bonding at the interface between ceramic particles and the matrix. Currently,  there are some instances of cracking at the bonding surface during the trial production. The casting direction angle of the bonding surface is believed to affect the occurrence of cracks. Our company is still conducting experiments to reduce the probability of cracking at the bonding surface. Once successful, we will gradually conduct trials at Jiang Copper Group's mines. The main application scenario is in areas with high wear and low impact, and the expected usage lifespan is anticipated to exceed that of previous high-chromium materials.