Mechanics of bioinspired lamellar structured ceramic/polymer composites: Experiments and models

Creation of super-tough ceramics is one of the main goals of materials science. Bioinspired design is shown to be the most effective method to achieve this goal. Previous studies on the mechanical performance of biological multilayered materials such as nacre have shown that their outstanding mechanical properties are direct results of the small-scale features and optimized arrangement of the elements in their microstructure. Hence, the freeze casting technique has been recently introduced as a novel method to create a new class of bioinspired polymer/ceramic composites. However, the method is cumbersome and the mechanics that controls the overall performance of these composites is not well-known. In this study, the mechanical performance of bioinspired alumina/polydimethylsiloxane (Al2O3/PDMS) and alumina/polyurethane (Al2O3/PU) composite samples with lamellar structure are experimentally and analytically investigated. Bioinspired multilayered samples with micron-size layers are fabricated using the challenging freeze casting technique. Different parameters such as solution concentration, freezing rate, and sintering temperature affect the structure, and subsequently, the mechanical performance of these multilayered materials. Moreover, in order to fully understand the underlying toughening and deformation mechanisms, a micromechanics model of the mechanical response of lamellar composites is presented. The closed-form solutions for the displacements of the layers as a function of constituent properties are derived to calculate the mechanical response of lamellar structured composites such as elastic modulus, strength, and tensile toughness. The experimental results agree well with the proposed analytical models. Fracture mechanics tests are also used to study the Resistance-Curve (R- Curve) behavior of the samples. Furthermore, important toughening mechanisms in these samples are discussed and governing equations for fiber bridging and fiber pull-out in lamellar ceramic/polymer composites are presented. Finally, detailed material design relationships are derived to identify future directions in the design of next generation structural composites.