3D printing and near-net shaping of laminated Cr3C2/Cu composites: Enhanced strength, toughness, and anisotropy

Ceramic/metal laminates offer great potential for enhancing mechanical properties; however, traditional fabrication methods lack precise microstructural control. This study employed direct ink writing (DIW) and pressureless infiltration to create near-net-shape Cr3C2/Cu laminates with tailored properties. Adjusting the Cr3C2 content and loading orientation yielded significant improvements in strength and toughness. Notably, a composite with 26.2 vol.% Cr3C2 exhibited a flexural strength of 995 MPa and a fracture toughness (KIC) of 22.3 MPa & sdot;m1/2 when loaded parallel to the layers (S-YOZ), exceeding values reported for conventionally manufactured counterparts. The enhanced mechanical properties and anisotropic behavior result from the synergy between the alternating soft Cu and hard Cr3C2 layers, the interpenetrating microstructures, and strong interfacial bonding. In situ observations and finite element simulations confirmed toughening mechanisms, including crack deflection, ductile bridging, and multiple cracking. This DIW-based approach offers a promising route for designing high-performance ceramic/metal composites.