Metal-ceramic composite material and method for forming the same

Abstract

A metal-ceramic composite material and a method for forming the same are provided. The metal-ceramic composite material includes a metal body, a plurality of metal oxide nanoparticles and a plurality of ceramic particles. The metal body includes a metal material having a first surface energy. The metal oxide nanoparticles and the ceramic particles are dispersed in the metal body. The ceramic particles have a second surface energy that is higher than the first surface energy.

What is claimed is: 
     
         1 . A metal-ceramic composite material, comprising:
 a metal body comprising a metal material having a first surface energy;   a plurality of metal oxide nanoparticles dispersed in the metal body; and   a plurality of ceramic particles dispersed in the metal body, wherein the ceramic particles have a second surface energy higher than the first surface energy.   
     
     
         2 . The metal-ceramic composite material as claimed in  claim 1 , wherein the first surface energy is less than 1.5 J/m 2 , and the second surface energy is higher than 2 J/m 2 . 
     
     
         3 . The metal-ceramic composite material as claimed in  claim 1 , wherein the metal oxide nanoparticles have a third surface energy, and a difference between the second surface energy and the third surface energy is less than 1 J/m 2 . 
     
     
         4 . The metal-ceramic composite material as claimed in  claim 1 , wherein the ceramic particles have a particle size of 0.5 μm to 20 μm. 
     
     
         5 . The metal-ceramic composite material as claimed in  claim 1 , wherein the metal oxide nanoparticles have a particle size of 3 nm to 50 nm. 
     
     
         6 . The metal-ceramic composite material as claimed in  claim 1 , wherein the metal oxide nanoparticles are present in an amount of less than 1 vol. % of the metal-ceramic composite material. 
     
     
         7 . The metal-ceramic composite material as claimed in  claim 1 , wherein the metal oxide nanoparticles are formed of a native oxide of the metal material having the first surface energy. 
     
     
         8 . The metal-ceramic composite material as claimed in  claim 7 , wherein the metal-ceramic composite material has grains and grain boundaries, and the metal oxide nanoparticles are formed within the grain boundaries. 
     
     
         9 . The metal-ceramic composite material as claimed in  claim 1 , wherein the metal oxide nanoparticles and the metal material having the first surface energy in total are present in an amount of 70-97 vol. % of the metal-ceramic composite material. 
     
     
         10 . The metal-ceramic composite material as claimed in  claim 1 , wherein the ceramic particles are present in an amount of 3-30 vol. % of the metal-ceramic composite material. 
     
     
         11 . The metal-ceramic composite material as claimed in  claim 1 , wherein the metal material having the first surface energy comprises aluminum, copper, iron, silicon, cobalt, lead, or a combination thereof, and the ceramic particles comprise silicon carbide, tungsten carbide, or a combination thereof. 
     
     
         12 . A method for forming a metal-ceramic composite material, comprising:
 mixing a metal starting material and a plurality of ceramic particles to form a mixture, wherein the metal starting material comprises a metal powder and a metal oxide interlayer formed on the surface of the metal powder, the metal powder comprises a metal material having a first surface energy, and the ceramic particles have a second surface energy higher than the first surface energy;   performing a pretreatment on the mixture to form a pretreated mixture, wherein the ceramic particles are attached to the metal oxide interlayer in the pretreated mixture; and   performing a fabrication process on the pretreated mixture to form the metal-ceramic composite material.   
     
     
         13 . The method for forming the metal-ceramic composite material as claimed in  claim 12 , wherein the metal oxide interlayer is formed of a native oxide of the metal powder, and the metal oxide interlayer has a thickness of 5 nm to 7 nm. 
     
     
         14 . The method for forming the metal-ceramic composite material as claimed in  claim 12 , wherein the pretreatment comprises heating, pressurizing, or a combination thereof. 
     
     
         15 . The method for forming the metal-ceramic composite material as claimed in  claim 12 , wherein performing the pretreatment comprises heating the mixture at 400° C. to 500° C. for 2 hours to 4 hours. 
     
     
         16 . The method for forming the metal-ceramic composite material as claimed in  claim 12 , wherein the fabrication process comprises a gas atomization process, a pouring casting process, a continuous casting process, a die casting process, a vacuum casting process, a low-pressure casting process, an additive manufacturing process, or any combination thereof. 
     
     
         17 . The method for forming the metal-ceramic composite material as claimed in  claim 12 , wherein the first surface energy is less than 1.5 J/m 2 , and the second surface energy is higher than 2 J/m 2 . 
     
     
         18 . The method for forming the metal-ceramic composite material as claimed in  claim 12 , wherein the ceramic particles have a particle size of 0.5 μm to 20 μm. 
     
     
         19 . The method for forming the metal-ceramic composite material as claimed in  claim 12 , wherein the metal starting material is present in an amount of 70-97 vol. % of the mixture. 
     
     
         20 . The method for forming the metal-ceramic composite material as claimed in  claim 12 , wherein the ceramic particles are present in an amount of 3-30 vol. % of the mixture.