Crafting a new composite: Researchers unite “Incompatible” metal and ceramic in a strong embrace, via constructing an interlocking interface

A persistent technical challenge in 3D printing of metal-cermet composites is interfacial cracking caused by significant residual stress from the mismatch in coefficients of thermal expansion during co-sintering. To address this, we pioneered a “vertical printing” strategy that actively constructs a three-dimensional, serrated, and interlocking interface during manufacturing, coupled with a solid-liquid phase sintering process to enhance interfacial bonding. The composite fabricated via this method demonstrated a bending strength 2.25 times greater than that of the monolithic ceramic, successfully suppressing delamination and cracking.

This work represents a paradigm shift in manufacturing—from passively coping with stress to actively designing interfaces—providing a new and viable solution for fabricating high-performance components intended for extreme environments. The work titled “Multimaterial 3D printing of high-strength metal-cermet inert anodes for aluminum electrolysis via interface-structure design”, was published in Advanced Powder Materials (Available online on 10 March 2026).