Abstract
A new processing technique, based on the colloidal infiltration of polymer sponges has been used to systematically vary gradient design. Polyurethane sponges (molded to contain a gradient in pore volume) were infiltrated with Al 2 O 3 slurry and subsequently fired to produce ceramic components with graded porosity. Partial sintering led to a bimodal porosity distribution in the preform, and subsequent melt infiltration with a wetting Cu-O alloy produced a dual-scale composite microstructure. Vickers indentation has been used for hardness profiling. Measured hardness values have been fit to a modified rule of mixtures to develop an expression relating hardness to ceramic volume fraction.
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