Mechanical and Functional Properties of Metal–Ceramic Composites for Harsh Environments

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Metallic Functional Materials".

Deadline for manuscript submissions: 31 October 2026 | Viewed by 1015

Editor


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Guest Editor
Institute of Ceramics, Refractories and Composite Materials,Technische Universität Bergakademie Freiberg, 09599 Freiberg, Germany
Interests: classical ceramic refractories; refractory metal composites; carbides including MAX-phases
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Special Issue Information

Dear Colleagues,

Materials used in harsh environments need to resist extreme conditions such as high temperatures, chemical attacks, and high mechanical loads, which often occurin combination. Ceramic–metal composites (ceramic-matrix or metal-matrix) usually combine unique functional properties to enhance the composites behavior under aggressive conditions.

The composite design needs to take into consideration the interface effects (bonding and chemical reactions) during synthesis and under application without degrading the functional properties (e.g., electrical and thermal conductivity, porosity, hardness, and toughness). In addition, the material design must satisfy the needs of circular economy.

In all cases, the composites must withstand harsh environments such as corrosion (e.g., contact with metallic and salt melts and reducing or oxidising atmospheres), thermal shock, thermal stresses, and/or mechanical loads.

This Special Issue encourages authors to contribute works related to the following topics:

  • Design and production of metal–ceramic composites.
  • Functional properties, e.g., electrical and thermal conductivity, porosity, hardness, toughness, etc.
  • Mechanical properties, e.g., characterisation of thermal shock behavior, strength at RT and high temperatures, etc.
  • Oxidation or corrosion resistance of functional materials and/or composites. 

We look forward to receiving your contributions.

Dr. Tilo Zienert
Guest Editor

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Keywords

  • thermal shock
  • thermal stresses
  • mechanical loads
  • corrosion
  • classical ceramic refractories
  • refractory metal composites

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Published Papers (2 papers)

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Research

23 pages, 6765 KB  
Article
Percolating Ta/Nb-Al2O3 Refractory Composites via Spark Plasma Sintering
by Gregory Kallien, Susanne Wagner and Karl Günter Schell
Metals 2026, 16(7), 742; https://doi.org/10.3390/met16070742 (registering DOI) - 5 Jul 2026
Abstract
The electrification of high-temperature industrial processes requires refractory materials that combine thermal stability with tailored electrical functionality. In this study, Ta/Nb-Al2O3 composites were prepared by spark plasma sintering (SPS) to investigate densification, metal-phase deformation, electrical conductivity and percolation behavior. Coarse, [...] Read more.
The electrification of high-temperature industrial processes requires refractory materials that combine thermal stability with tailored electrical functionality. In this study, Ta/Nb-Al2O3 composites were prepared by spark plasma sintering (SPS) to investigate densification, metal-phase deformation, electrical conductivity and percolation behavior. Coarse, fine and superfine alumina powders were combined with tantalum or niobium and sintered at 1300–1600 °C for 5 min with 50 MPa uniaxial pressure. The results show that the alumina particle size and morphology strongly influence the formation of conductive metal networks. Coarse alumina promotes deformation and elongation of the metallic phase, thereby improving metal-phase connectivity and lowering the operational percolation threshold. Fine and superfine alumina enhance densification but can delay percolation by embedding metal particles in a dense ceramic matrix. Combining these fractions, both effects can be balanced, enabling improved densification while maintaining effective conductive pathways. An operational percolation threshold of 7.5 vol.-% was obtained for Ta/coarse alumina, indicating highly effective metal-phase connectivity after SPS. Microstructural analysis supports the interpretation that matrix-controlled metal-particle deformation and spatial distribution govern the electrical response. Tailored alumina matrix design can reduce the refractory metal content required for conductive ceramic–metal composites. Full article
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27 pages, 4055 KB  
Article
Additive Manufacturing of Layered Nb-Al2O3 Composite Granules Based on Paste Extrusion
by Tilo Zienert, Dinesh Kumar Gunasekar, Dirk Endler, Christina Faßauer and Christos G. Aneziris
Metals 2026, 16(1), 101; https://doi.org/10.3390/met16010101 - 16 Jan 2026
Cited by 2 | Viewed by 648
Abstract
How would it be possible to functionalize ceramic aggregates for use in refractories? In this work, we demonstrate how paste extrusion can be used to fabricate layered and porous Nb-Al2O3-based composite refractories for adjusting thermal and electrical conductivity. Additive [...] Read more.
How would it be possible to functionalize ceramic aggregates for use in refractories? In this work, we demonstrate how paste extrusion can be used to fabricate layered and porous Nb-Al2O3-based composite refractories for adjusting thermal and electrical conductivity. Additive manufacturing is used to generate a specific sequence of alumina and composite layers. After drying, the samples were sintered at 1600 °C, crushed, and sieved into particle sizes up to 3150 µm. The rheology of the paste revealed the intended shear-thinning behavior with microcrack formation between the yield and flow strain. The sintered material showed promising thermal-shock characteristics reaching plateau values after the third cycle without signs of further structural damage up to the fifth thermal shock. The layered microstructure was retained after crushing the composites, establishing functionalization of the refractory granules for all particle sizes. Full article
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