Fabrication of ZrB2–Zr cermet using laser sintering technique

Abstract A combination of laser sintering/melting and induction heating techniques is used to fabricate ZrB 2 –Zr ceramic–metal composite (cermet) 3-D structures using layer by layer deposition. It is shown that the interface between layers comprises an ~ 20 µm thick Zr-rich phase near the remelted zone. The starting powder mixtures consist of 30–50 wt.% Zr, which is used to assist binding of ZrB 2 particles. Sintered objects have densities > 95% of theoretical values and have microhardness values up to 16.0 GPa. ZrB 2 –Zr cermet may reduce the likelihood of mechanical failures by increasing toughness and impact resistance contributed from the continuous Zr matrix, yet preserve good abrasive characteristics provided by ZrB 2 grains. The proposed method allows fabricating complex-shaped structures, and joining or repairing objects made from analogous ultra-high temperature materials.