Materials with high specific strength and toughness are urgently needed in the fields of electronic packaging, armor, and aerospace. SiC/Al composites show good potential for these applications but the problem of mutual exclusion of strength and toughness still needs to be solved. Herein, we propose a new strategy to simultaneously enhance its strength and toughness from the perspective of structural optimization and interface enhancement. Inspired by the nacre structure, a 3D-(SiC–Si3N4)/Al co-continuous composite was prepared by freeze-casting combined with the pressure infiltration method. During the process, elongated Si3N4 grains were introduced into the ceramic framework to design the internal lamella wall structure and increase the contact area with the aluminum substrate. Moreover, a favorable interfacial bonding was designed between Si3N4 and Al to improve interface wettability. The reliable microstructure of porous 3D-(SiC–Si3N4) preform was tailored through the adjustment of initial solid loading and the α-Si3N4 component. The effects of initial solid loading and the α-Si3N4 component on the microstructure, interfacial wettability, and mechanical properties of the final composites were investigated. The results showed that the SiC–Si3N4/Al composites possess high flexural strength (769 MPa) and fracture toughness (15.1 MPa m1/2), which is superior to data reported in general literature. Numerous elongated β-Si3N4 grains are produced on the ceramic skeleton, forming an interlocking structure with the aluminum matrix, which increases the contact area with the aluminum substrate. A chemical reaction layer was formed at the interface of the composite, greatly improving the interfacial bonding strength. This work provides a promising design guideline for developing and optimizing high-strength and tough composite.
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