Strong and tough ZrB₂ materials using a heterogeneous ceramic–metal layered architecture

ZrB₂-SiC_w ceramic sheets produced by tape casting and tailored ductile Ti foil were alternatively stacked and sintered by spark plasma to synthesize a multi-layered ceramic. Following mechanical processing, a high flexural strength (621 MPa) and fracture toughness (15.3 MPa·m^1/2) in uniaxial tension were achieved in comparison to laminated ceramics with a weak BN interlayer. Scanning and transmission electron microscopy revealed a characteristic macroscopic heterogeneous lamella as well as a three-tier microstructured interface, termed the L-T structure. This novel structure provides a new path for the development of ceramic/metal layered composites with superior mechanical properties in the near future.