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Novel Metal-Matrix Composites Prepared by Paper Manufacturing Technology

The current contribution deals with metal-matrix composites prepared by paper manufacturing technology. In contrast to conventional techniques, this technology is an energy-and cost-efficient process for the shaping of thin sheets using solid powder mixtures. Conventional and pre-ceramic as well as pre-metallic paper-manufacturing have in common that cellulose (pulp) fibres are loaded with inorganic fillers. The present study is focused on the paper web formation using a metastable austenitic steel powder (16-7-3 %Cr-%Mn-%Ni) and a magnesia partially stabilised zirconia powder as inorganic fillers. The paper web formation was investigated. During filtration of the aqueous fibre-filler suspension the steel particles were incorporated in-between the fibre network and steel clusters were formed. Thus, solid retentions of > 90 wt.% were achieved. Calendering had a positive influence on porosity, bulk density, and tensile strength of the green paper sheets. The development of an optimized debinding process is presented and the microstructural changes as well as phase formations during firing are discussed in response to the residual carbon content. The sintered composites attained ultimate tensile strengths of up to 177 N/ mm2 at a total porosity of 66 %. These metal-matrix composites are promising materials for the shaping of light-weight structures.