Multiphase Metal-Ceramic Composite via Sintering
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Solution Overview
Problem
Existing methods for producing multi-phase materials are limited to ductile metals, restrict the use of ceramic materials, require numerous manual process steps, and are not suitable for large-scale production, resulting in limited surface hardness and restricted material combinations.
Innovation Solution
A multi-phase material with an intercalation or three-dimensional interpenetration structure, where phases are distinguishable macroscopically and produced through sintering of powders, allowing for a wide range of materials including ceramics and metals, and enabling automation and scalability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple forming steps with diffusion bonding are used to create multi-phase materials, then visually striking multi-colored patterns are achieved, but the process requires numerous manual steps and is limited to ductile metals
Solution Approach 1:
The invention changes the fundamental processing parameters from room-temperature diffusion bonding to high-temperature sintering (above melting point of at least one component). This parameter change enables the use of ceramic materials and metals with limited ductility, expanding material versatility while simplifying the overall process by eliminating multiple intermediate forming and annealing steps
Solution Approach 2:
The invention replaces the mechanical deformation-based forming process with a thermal sintering process. Instead of mechanically deforming ductile metals at room temperature, the invention uses heat and pressure to sinter powder mixtures, substituting mechanical working with thermal processing to achieve phase bonding and pattern formation
2Shape
If high degree of deformation is applied to achieve multi-phase patterns, then visually appealing macrostructures are created, but surface hardness is limited due to ductility requirements
Solution Approach 1:
The invention changes the processing temperature parameter to above the melting point of at least one component, enabling sintering instead of cold deformation. This allows achieving both complex macrostructures and high surface hardness simultaneously, as the sintering process creates strong bonds without requiring material ductility
Solution Approach 2:
The invention uses composite powder mixtures containing ceramics and/or metals in specific ratios. The resulting sintered composite materials achieve high hardness and wear resistance while maintaining visually striking macrostructures, combining the benefits of different material phases
3Reliability
If traditional diffusion bonding process is used, then multi-layer semi-finished products are created, but the process is time-consuming and not suitable for large-scale production
Solution Approach 1:
The invention merges multiple separate process steps (layering, diffusion bonding, intermediate annealing, re-deformation) into a single integrated sintering operation. By consolidating these steps, the invention maintains reliable phase bonding while dramatically increasing production speed and enabling automation
Solution Approach 2:
The invention performs preliminary mixing and distribution of phases in powder form before sintering. This preliminary action ensures uniform phase distribution and bonding interfaces are established before the final high-temperature process, guaranteeing bonding quality while reducing subsequent processing steps
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach expands material combinations, reduces process steps, eliminates ductility limitations, and achieves high hardness and wear resistance, making it suitable for luxury and technical applications with unique macrostructures.
Implementation Method 1
the first phase is produced from powders in the course of the manufacturing process by sintering
Implementation Method 2
connected to one another to form a multi-layer semi-finished product via a (2) diffusion process that takes place under pressure and temperature
Data Source
AI summary
The invention relates to a material having a multiphase structure, comprising at least one first solid phase and at least one second solid phase, which material is characterized in that the first phase and the second phase are each a metal, a metal alloy, a ceramic material or combinations thereof in the form of a composite material, the phases of the structure can be distinguished from one another macroscopically, the multiphase structure is formed as an embedding structure or as a three-dimensional penetration structure, wherein the embedding structure has the first phase as a matrix phase occurring continuously in three spatial dimensions, and the second phase as a discontinuous, statistically distributed embedding phase, and wherein the first phase is produced by sintering.