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Heterogeneous interface control in direct ink writing of functionally graded ceramics
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DOI：10.1016/j.addma.2026.105336.png)
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Abstract
En 中文
Direct Ink Writing (DIW) provides a promising approach for fabricating multi-material functionally graded ceramics. However, existing studies mainly focus on the fabrication of biomimetic gradient structures, while systematic investigations on the coupling relationship among compositional gradients, sintering conditions, and heterogeneous interface quality remain limited, particularly regarding interface failure and stress regulation mechanisms. To address this issue, a ZrO2-Al2O3 functionally graded ceramic system based on in-situ dynamic mixing during DIW was developed. The effects of different compositional gradients and sintering temperatures on interfacial structural evolution and mechanical performance were systematically evaluated. By combining microstructural characterization and mechanical testing with a thermal expansion mismatch model, the stress distribution and crack formation mechanisms at the ZrO2-Al2O3 compositional-gradient interface were comprehensively analyzed. The results show that the compositional gradients fabricated via the in-situ mixing strategy significantly enhance the interfacial integrity of the ZrO2-Al2O3 interface. A lower compositional gradient together with an appropriate sintering temperature effectively reduces interfacial stress and suppresses strain localization, resulting in a substantial increase in interfacial bonding strength from 4.90 MPa to 22.72 MPa. This study establishes the intrinsic correlation among compositional gradient design, stress regulation, and the strength of the ZrO2-Al2O3 interface, providing a theoretical basis for interface engineering and stress adjustment in multi-material graded ceramics.
Keywords:
Functionally graded materials (FGMs)
Additive manufacturing
Heterogeneous interface
Dynamic mixing
Direct ink writing
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