Nanoarchitected metal/ceramic interpenetrating phase composites

Metal Nanocomposites Reinforced by Ceramic Nanoarchitecture: Exploiting Extrinsic Size Effects for High Mechanical Strength

The pursuit of harnessing superior mechanical properties achieved through the size effect on a macroscopic scale has been a prominent focus in engineering, as size-induced strengthening is enabled only in the nanoscale regime. This study presents a metal/ceramic/metal (MCM) nanocomposite reinforced by ceramic nanoarchitectures. Through proximity-field nanopatterning, the inch-scale production of nanoarchitecture films is enabled in a single fabrication step. The developed three-dimensional (3D) Ni/Al2O3/Ni nanocomposite film exhibits significantly high compressive strength, corresponding to an increase of approximately 30% compared with that calculated using the upper limits of the conventional rule of mixtures. The exceptional strength of the 3D MCM nanocomposite can be attributed to the extrinsic size effect of the ceramic nanoarchitectures. By combining size-induced strengthening of ceramics with the strengthening law for composites, a new type of strengthening model is derived and experimentally validated using the 3D MCM nanocomposite.

Interpenetrating LiB/Li3BN2 phases enabling stable composite lithium metal anode

Host-less lithium metal anode generally suffers from large volume changes and serious dendrite growth during cycling, which poses challenges for its practical application. Interpenetrating phase composites with continuous architectures offer a solution to enhance mechanical properties of materials. Herein, a robust composite Li anode (LBN) material is fabricated through the metallurgical reaction between Li and hexagonal boron nitride (h-BN) with the formation of interpenetrating LiB/Li3BN2 phases. As LiB fibers are anchored by Li3BN2 granules, the collapse and slippage of LiB fibers are suppressed whilst the mechanical strength and structural stability of LBN are reinforced. By rolling, ultrathin (15 μm), freestanding, and electrochemically stable LBN foil can be obtained. The LBN anode exhibits a high average Coulombic efficiency of 99.69% (1 mA cm-2, 3 mAh cm-2) and a long lifespan of 2500 h (1 mA cm-2, 1 mAh cm-2). Notably, the LiCoO2 (with double-sided load 40 mg cm-2)|LBN pouch cell can operate over 450 cycles with a capacity retention of 90.1%. The exceptional cycling stability of LBN can be ascribed to the interpenetrating reinforcement architectures and synergistic electronic/ionic conductivity of the LiB/Li3BN2 dual-lithiophilic-phases. This work provides a new methodology for thin Li strip processing and reinforced-architecture design, with implications beyond battery applications.

Well-Ordered Bicontinuous Nanohybrids from a Bottom-Up Approach for Enhanced Strength and Toughness

Biomimicking natural structures to create structural materials with superior mechanical performance is an area of extensive attention, yet achieving both high strength and toughness remains challenging. This study presents a novel bottom-up approach using self-assembled block copolymer templating to synthesize bicontinuous nanohybrids composed of well-ordered nanonetwork hydroxyapatite (HAp) embedded in poly(methyl methacrylate) (PMMA). This structuring transforms intrinsically brittle HAp into a ductile material, while hybridization with PMMA alleviates the strength reduction caused by porosity. The resultant bicontinuous PMMA/HAp nanohybrids, reinforced at the interface, exhibit high strength and toughness due to the combined effects of topology, nanosize, and hybridization. This work suggests a conceptual framework for fabricating flexible thin films with mechanical properties significantly surpassing those of traditional composites and top-down approaches.

Damage-programmable design of metamaterials achieving crack-resisting mechanisms seen in nature

The fracture behaviour of artificial metamaterials often leads to catastrophic failures with limited resistance to crack propagation. In contrast, natural materials such as bones and ceramics possess microstructures that give rise to spatially controllable crack path and toughened material resistance to crack advances. This study presents an approach that is inspired by nature's strengthening mechanisms to develop a systematic design method enabling damage-programmable metamaterials with engineerable microfibers in the cells that can spatially program the micro-scale crack behaviour. Machine learning is applied to provide an effective design engine that accelerate the generation of damage-programmable cells that offer advanced toughening functionality such as crack bowing, crack deflection, and shielding seen in natural materials; and are optimised for a given programming of crack path. This paper shows that such toughening features effectively enable crack-resisting mechanisms on the basis of the crack tip interactions, crack shielding, crack bridging and synergistic combinations of these mechanisms, increasing up to 1,235% absorbed fracture energy in comparison to conventional metamaterials. The proposed approach can have broad implications in the design of damage-tolerant materials, and lightweight engineering systems where significant fracture resistances or highly programmable damages for high performances are sought after.

Toward Multiscale, Multimaterial 3D Printing

Biological materials and organisms possess the fundamental ability to self-organize, through which different components are assembled from the molecular level up to hierarchical structures with superior mechanical properties and multifunctionalities. These complex composites inspire material scientists to design new engineered materials by integrating multiple ingredients and structures over a wide range. Additive manufacturing, also known as 3D printing, has advantages with respect to fabricating multiscale and multi-material structures. The need for multifunctional materials is driving 3D printing techniques toward arbitrary 3D architectures with the next level of complexity. In this paper, the aim is to highlight key features of those 3D printing techniques that can produce either multiscale or multimaterial structures, including innovations in printing methods, materials processing approaches, and hardware improvements. Several issues and challenges related to current methods are discussed. Ultimately, the authors also provide their perspective on how to realize the combination of multiscale and multimaterial capabilities in 3D printing processes and future directions based on emerging research.

Observing and Modeling the Wear Process of Heterogeneous Interface

Understanding and controlling the wear process of heterogeneous interfaces between soft and hard phases is crucial for designing and fabricating materials, such as improving the wear resistance of particle reinforced metal matrix composites and the accuracy and efficiency of chemical mechanical polishing. However, the wear process can be hardly observed, as interfaces are buried under the surface. Here, we proposed a nanowear test method by combining focused ion beam cutting to expose interfaces, atomic force microscopy to rub against interfaces, and scanning electron microscope to characterize the interface damage. Using this method, three typical wear forms had been observed in Al/SiC composite, i.e., merely matrix wear, particle fracture, and particle pullout. A theoretical model was proposed that revealed that the increasing interfacial friction would induce particle fracture or pullout, depending on the particle edge angle and tip edge angle. This work sheds light on wear control in composites and nanofabrication.

Mechanical Performance of Copper-Nanocluster-Polymer Nanolattices

A type of copper-nanocluster-polymer composites is reported and showcased that their 3D nanolattices exhibit a superior combination of high strength, toughness, deformability, resilience, and damage-tolerance. Notably, the strength and toughness of ultralight copper-nanocluster-polymer nanolattices in some cases surpass current best performers, including alumina, nickel, and other ceramic or metallic lattices at low densities. Additionally, copper-nanocluster-polymer nanolattices are super-resilient, crack-resistant, and one-step printed under ambient condition which can be easily integrated into sophisticated microsystems as highly effective internal protectors. The findings suggest that, unlike traditional nanocomposites, the laser-induced interface and the high fraction of ultrasmall Cu15 nanoclusters as crosslinking junctions contribute to the marked nonlinear elasticity of copper-nanocluster-polymer network, which synergizes with the lattice-topology effect and culminates in the exceptional mechanical performance.

A Triply-Periodic-Minimal-Surface Structured Interphase based on Fluorinated Polymers Strengthening High-energy Lithium Metal Batteries

The challenge of constructing a mechanically robust yet lightweight artificial solid-electrolyte interphase layer on lithium (Li) anodes highlights a trade-off between high battery safety and high energy density. Inspired by the intricate microstructure of the white sea urchin, we first develop a polyvinyl fluoride-hexafluoropropylene (PVDF-HFP) interfacial layer with a triple periodic minimal surface structure (TPMS) that could offer maximal modulus with minimal weight. This design endows high mechanical strength to an ordered porous structure, effectively reduces local current density, polarization, and internal resistance, and stabilizes the anode interface. At a low N/P ratio of ~3, using LiFePO4 as the cathode, Li anodes protected by TPMS-structured PVDF-HFP achieve an extremely low capacity-fading-rate of approximately 0.002 % per cycle over 200 cycles at 1 C, with an average discharge capacity of 142 mAh g-1. Meanwhile, the TPMS porous structure saves 50 wt % of the interfacial layer mass, thereby enhancing the energy density of the battery. The TPMS structure is conducive to large-scale additive manufacturing, which will provide a reference for the future development of lightweight, high-energy-density secondary batteries.

Effect of Particle Strength on SiCp/Al Composite Properties with Network Architecture Design

Recent works have experimentally proven that metal matrix composites (MMCs) with network architecture present improved strength-ductility match. It is envisaged that the performance of architecturally designed composites is particularly sensitive to reinforcement strength. Here, reinforcing particles with various fracture strengths were introduced in numerical models of composites with network particle distribution. The results revealed that a low particle strength (1 GPa) led to early-stage failure and brittle fracture. Nevertheless, a high particle strength (5 GPa) delayed the failure behavior and led to ductile fracture at the SiC/Al-Al macro-interface areas. Therefore, the ultimate tensile strengths (UTS) of the network SiC/Al composites increased from 290 to 385 MPa, with rising particle strength from 1 to 5 GPa. Based on the composite property, different particle fracture threshold strengths existed for homogeneous (~2.7 GPa) and network (~3.7 GPa) composites. The higher threshold strength in network composites was related to the increased stress concentration induced by network architecture. Unfortunately, the real fracture strength of the commercial SiC particle is 1-2 GPa, implying that it is possible to select a high-strength particle necessary for efficient network architecture design.

Realizing reversible phase transformation of shape memory ceramics constrained in aluminum

Small-scale shape memory ceramics exhibit superior shape memory or superelasticity properties, while their integration into a matrix material and the subsequent attainment of their reversible tetragonal-monoclinic phase transformations remains a challenge. Here, cerium-doped zirconia (CZ) reinforced aluminum (Al) matrix composite is fabricated, and both macroscopic and microscopic mechanical tests reveal more than doubled compressive strength and energy absorbance of the composites as compared with pure Al. Full austenitization in the CZ single-crystal clusters is achieved when they are constrained by the Al matrix, and reversible martensitic transformation triggered by thermal or stress stimuli is observed in the composite micro-pillars without causing fracture in the composite. These results are interpreted by the strong geometric confinement offered by the Al matrix, the robust CZ/Al interface and the local three-dimensional particle network/force-chain configuration that effectively transfer mechanical loads, and the decent flowability of the matrix that accommodates the volume change during phase transformation.

A sinterless, low-temperature route to 3D print nanoscale optical-grade glass

Three-dimensional (3D) printing of silica glass is dominated by techniques that rely on traditional particle sintering. At the nanoscale, this limits their adoption within microsystem technology, which prevents technological breakthroughs. We introduce the sinterless, two-photon polymerization 3D printing of free-form fused silica nanostructures from a polyhedral oligomeric silsesquioxane (POSS) resin. Contrary to particle-loaded sacrificial binders, our POSS resin itself constitutes a continuous silicon-oxygen molecular network that forms transparent fused silica at only 650°C. This temperature is 500°C lower than the sintering temperatures for fusing discrete silica particles to a continuum, which brings silica 3D printing below the melting points of essential microsystem materials. Simultaneously, we achieve a fourfold resolution enhancement, which enables visible light nanophotonics. By demonstrating excellent optical quality, mechanical resilience, ease of processing, and coverable size scale, our material sets a benchmark for micro- and nano-3D printing of inorganic solids.

Macroscale Fabrication of Lightweight and Strong Porous Carbon Foams through Template-Coating Pair Design

Manufacturing of low-density-high-strength carbon foams can benefit the construction, transportation, and packaging industries. One successful route to lightweight and mechanically strong carbon foams involves pyrolysis of polymeric architectures, which is inevitably accompanied by drastic volumetric shrinkage (usually >98%). As such, a challenge of these materials lies in maintaining bulk dimensions of building struts that span orders of magnitude difference in length scale from centimeters to nanometers. This work demonstrates fabrication of macroscale low-density-high-strength carbon foams that feature exceptional dimensional stability through pyrolysis of robust template-coating pairs. The template serves as the architectural blueprint and contains strength-imparting properties (e.g., high node density and small strut dimensions); it is composed of a low char-yielding porous polystyrene backbone with a high carbonization-onset temperature. The coating serves to imprint and transcribe the template architecture into pyrolytic carbon; it is composed of a high char-yielding conjugated polymer with a relatively low carbonization-onset temperature. The designed carbonization mismatch enables structural inheritance, while the decomposition mismatch affords hollow struts, minimizing density. The carbons synthesized through this new framework exhibit remarkable dimensional stability (≈80% dimension retention; ≈50% volume retention) and some of the highest specific strengths (≈0.13 GPa g^-1 cm³ ) among reported carbon foams derived from porous polymer templates.