Pressure‐Induced Interfacial Micro‐interlocking for Improving the Bonding Reliability of Zirconia‐Toughened Alumina Ceramic Reinforced Iron Composites

The inadequate wettability and insufficient interfacial bonding between the ceramic reinforcing phases and the metal matrix remain challenges. This study focuses on zirconia‐toughened alumina ceramic reinforced high chromium cast iron composites, which are prepared using an innovative “flow mixing + pressure compositing” method derived from liquid die forging technology. The microstructure and phase composition of the prepared composites are examined, and the distribution of particles inside the matrix and the interfacial state are characterized. The formation conditions of the interface are analyzed from both thermodynamic and dynamic perspectives, and the formation process and bonding mechanism of the interface are discussed. Additionally, corresponding experimental analyses are conducted, and the interfacial bonding state under different pressures are also investigated. The results indicate that the interfacial bonding rate increases gradually with increasing pressure. Specifically, when the pressure increases from 40 to 100 MPa, the interfacial bonding rate escalates from 37.71% to 98.89%, with an increase of 162.2%, indicating the interface consistently approaches complete bonding as pressure increases. The formation of the interface undergoes four phases: the contact phase, the preliminary bonding phase, the reinforced bonding phase, and the complete bonding phase.