CHEN Xiaoyi, LI Liusong, GUO Huan, et al. Research progress and challenges in manufacturing fiber reinforced ceramic matrix composites using direct ink writing technology[J]. Acta Materiae Compositae Sinica, 2025, 42(2): 577-595. DOI: 10.13801/j.cnki.fhclxb.20240617.002
Citation: CHEN Xiaoyi, LI Liusong, GUO Huan, et al. Research progress and challenges in manufacturing fiber reinforced ceramic matrix composites using direct ink writing technology[J]. Acta Materiae Compositae Sinica, 2025, 42(2): 577-595. DOI: 10.13801/j.cnki.fhclxb.20240617.002

Research progress and challenges in manufacturing fiber reinforced ceramic matrix composites using direct ink writing technology

Funds: Liaoning Provincial Natural Science Foundation (2023MS094); Open Funding Project of Shaanxi Key Laboratory of Aerospace Composite (ZX20220525)
More Information
  • Received Date: April 18, 2024
  • Revised Date: May 16, 2024
  • Accepted Date: June 02, 2024
  • Available Online: June 24, 2024
  • Published Date: June 17, 2024
  • Advanced ceramics and composites have been widely used in aerospace applications because of their excellent performance, at present, the use of three-dimensional (3D) printing technology to achieve rapid, efficient, and low-cost preparation of such materials has become a central issue. Compared with the traditional process, the 3D printing of ceramic materials is generally faced with the problem of their inherent brittleness and low damage tolerance. Therefore, the incorporation of fiber reinforcements in printed parts to overcome the challenges of poor fracture toughness of advanced ceramics has become a hot topics and frontier. Here, this work systematically summarize recently developed direct ink writing (DIW) technologies for printing fiber reinforced ceramic matrix composites (FRCMC), focus on the relationship between the processing, structure, and properties of DIW-FRCMCs, comprehensively analyze the ceramic ink design process, the fiber introduction method, the densification technologies and the important properties of the printed parts. In the last, the important issues were pointed out and future research directions were prospected.

  • Objectives 

    In the field of national defense and security, the demand for cutting-edge breakout technologies has become particularly urgent, and hypersonic vehicles with high mobility, strong breakout capabilities, low-cost inputs, and high reliability are the key technological means to achieve the key strategic goals of air and space integration and offensive and defensive preparedness. The challenge of thermal protection has become a major technological bottleneck limiting the progress of hypersonic vehicles, and the fabrication and structural design of fiber-toughened ceramic matrix composites (FRCMCs) with complex shapes, excellent performance, and structural-functional integration have become the key to technological breakthroughs, and the Direct Ink Write (DIW) process, which can achieve near-net-shape at the level of the ceramic matrix composites components, provides a possible way to solve the problem. possible way to solve this challenge. Based on the latest research progress of DIW-FRCMCs at home and abroad, this paper introduces the ink design theory and method, fiber introduction path and corresponding toughening mechanism, the post-densification process of DIW-printed preforms, as well as some key performances of DIW-FRCMCs in terms of the characteristics of the process, and finally, points out the problems of the existing research, and proposes the research directions that should be focused on. Finally, the problems of existing research are pointed out, and the research directions should be emphasized.

    Methods 

    By summarizing the research literature on the preparation of FRCMCs by the DIW process at home and abroad in recent years, the component design of ceramic ink in the DIW process and its related mechanism of action are firstly briefly described, followed by the description of the fiber introduction methods of the short-fiber-toughened ceramic matrix composites and continuous-fiber-toughened ceramic matrix composites, the challenges of their introduction, and their toughening effects after their introduction, and the printing of composites preforms by the post-densification processes, which ensure that the printed parts have high structural strength, and finally summarizes some key properties of DIW-FRCMCs, including fracture toughness, flexural strength, and tensile strength, and discusses the prospects and research directions for the application of this type of printing method in fiber-toughened ceramic matrix composites.

    Results 

    By summarizing and discussing four aspects of the existing ink direct printing methods for manufacturing fiber-toughened ceramic matrix composites: the design of the ink and its principle, the way of fiber introduction, the selection of densification process, and the key performance of the printed components, it is pointed out that in the extreme service environments of today's new-technology featured vehicles, the ceramic-based structural components with simple structure, fragmentation, and low performance can no longer meet the requirements. Therefore, the rapid development of three-dimensional printing technology provides an important technical way for manufacturing ceramic matrix composites, in which DIW technology embodies great application prospects in the field of three-dimensional printing of fiber-tough ceramic matrix composites due to the simple equipment, controllable process, and the ability to large-size molding. However, the DIW-printed blanks suffer from low densities and low strengths, and need to be combined with densification processes to obtain structural composites with low porosity.Conclusions: At present, the research on DIW-FRCMCs is very limited, and there are still many challenges to its practical application, for this reason, there is still a need to carry out in-depth and systematic research work in the following aspects: (1) The existing ceramic inks are mainly aimed at SiC ceramic substrates, and the inks for other ceramics, such as boron carbide, ultra-high temperature ceramics and other substrates, have not been systematically designed and prepared, and the viscoelasticity of the corresponding inks, Viscoelasticity, shear thinning and other characteristics of the corresponding ink need to be systematically studied. (2) Existing research has not systematically constructed the interaction and formation process of heterogeneous interface structure between fiber and ink, and the influence of fiber toughness construction characteristics on the printing of interlayer bonding characteristics and interfacial bonding strength has not been discussed in depth, and the evolution of interfacial characteristics in the printing process needs to be explored. (3) At present, there are very few studies on the densification method of DIW-printed porous preforms, which need to improve the densification efficiency of DIW-printed preforms by using advanced pore characterization methods to quantitatively express the characteristics of the spatial distribution of the pores and re-optimize the densification process. (4) At present, the structured design mainly focuses on the additive manufacturing of polymer and metal materials, while there are fewer studies on the integrated realization of structure-function for the additive manufacturing of advanced ceramic matrix composites. Combined with the integration of topology optimization and machine learning fields, the performance design needs to be integrated into the realization of additive manufacturing process based on the service environment of the material. (5) The experimental research on the improvement of printing parameters and equipment has a long cycle time, and the data are discrete and poorly reproducible, so the printing process can be simulated by numerical simulation methods, and this kind of research will help to reveal various complex mechanisms in the process of the DIW process, and deeply understand the printing process of the DIW process.

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