Fabrication and characterization of Al₂O₃-Ni gradient composites for aggressive substance transport using centrifugal gelcasting

Justyna Zygmuntowicz; Joanna Tańska; Paulina Wiecińska; Paulina Piotrkiewicz; Katarzyna Konopka; Mikołaj Szafran; Marcin Wachowski; Janusz Torzewski; Waldemar Kaszuwara

doi:10.1007/s40436-026-00603-1

Advances in Manufacturing ›› :1 -17. DOI: 10.1007/s40436-026-00603-1

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Fabrication and characterization of Al₂O₃-Ni gradient composites for aggressive substance transport using centrifugal gelcasting

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¹Faculty of Materials Science and Engineering, Warsaw University of Technology, 02-507, Warsaw, Poland

²Faculty of Chemistry, Warsaw University of Technology, 00-664, Warsaw, Poland

³Faculty of Mechanical Engineering, Military University of Technology, 00-908, Warsaw, Poland

^a justyna.zygmuntowicz@pw.edu.pl

Justyna Zygmuntowicz

Justyna Zygmuntowicz is an assistant professor at Faculty of Materials Science and Engineering in Division of Construction and Functional at Warsaw University of Technology. Her research work focuses on ceramic matrix composites, including ceramic-metal and ceramic-ceramic composites obtained by various methods using powders as starting materials. In particular, the scope of experimental work includes the development of new methods for manufacturing composites like Al₂O₃-Ni, Al₂O₃-Mo, Al₂O₃-Cu-Mo, Al₂O₃-Cu-Ni, Al₂O₃-Ni-Ti, and ZTA with assumed properties and the characterization of their structure and properties.

Joanna Tańska

Joanna Tańska is a Ph.D. student at Doctoral School of Warsaw University of Technology in the discipline of Chemical Engineering. She is a member of the Polish Ceramic Society. Her research focuses on the preparation of ceramic and composite materials using multiphase colloidal systems, with a particular emphasis on 3D printing techniques such as digital light processing (DLP) and direct ink writing (DIW). She gained her scientific experience at Faculty of Chemistry, as well as during a three-month internship at National Institute for Materials Science NIMS in Japan.

Paulina Wiecińska

Paulina Wiecińska is an associate professor at Warsaw University of Technology, Faculty of Chemistry; since 2010, she has been a research and teaching employee at Department of Chemical Technology. She was the guest researcher at National Institute for Materials Science (NIMS) in Japan, and in 2011, she carried out postdoctoral research at the EMPA Institute in Switzerland. Since 2019, she has been the head of the Advanced Ceramics Group at Warsaw University of Technology. Currently, she is also the vice-president of Polish Ceramic Society. Her scientific activity concerns the development of technologies aimed at advanced ceramics and composite materials with various structures and geometries, using environmentally friendly organic additives and multiphase colloidal systems. She has expertise in the field of rheology of fluids, mechanical properties of ceramics and thermal analysis.

Paulina Piotrkiewicz

Paulina Piotrkiewicz is currently finishing her Ph.D. degree at Faculty of Materials Science and Engineering, Warsaw University of Technology. She has participated in several research projects in the field of ceramic-metal and ceramic-ceramic composites. Her research work mainly focuses on ceramic-metal composites and the influence of the multi-metallic phase on their fabrication and properties.

Katarzyna Konopka

Katarzyna Konopka is a professor in area of materials science and engineering. She has been working as scientist and university teacher at Warsaw University of Technology in Warsaw, Poland. Her research focuses on the field of ceramics, ceramic matrix composites, biomimetics as well as characterization of microstructures and properties of various engineering materials. She is also experienced in investigation of ancient pottery.

Mikołaj Szafran

Mikołaj Szafran is a member (academician) of World Academy of Ceramics – Class Science and a fellow of the European Ceramic Society. He is a chemist specializing in the technology of advanced ceramic materials and is working on designing and processing these ceramic materials based generally on chemistry. In his work, he tried to combine/use his knowledge of organic, inorganic and physical chemistry to understand the relations between properties of raw materials, green and sintered bodies. Now his main scientific interests include the application of colloidal chemistry in processing advanced ceramic materials and composites, including ceramic-metal composites and ceramic-polymer composites.

Marcin Wachowski

Marcin Wachowski is an associate professor at Institute of Robots and Machine Design of Military University of Technology (MUT) and head of Fatigue and Machine Design Department. His research fields are layered materials obtained by advanced joining methods. He is also studying hybrid ceramic-metal composites with gradient reinforcement and innovative gradient ceramic-ceramic composites. He performs research on structural materials, in particular metallic and ceramics composites. Thus, his research areas cover a wide spectrum of topics in the field of materials and mechanical engineering, including layered materials, ceramic-metal composite materials, and advanced joining techniques.

Janusz Torzewski

Janusz Torzewski is an assistant professor at Faculty of Mechanical Engineering of Military University of Technology. He received his Ph.D. in Civil Engineering from Military University of Technology in 2007. He conducts research in area of the fatigue strength of structural materials, in particular aluminium and titanium alloys and high-strength steels. His scientific interests focus on research on the strength of structural materials manufactured using additive techniques, modern high-energy methods and their joining. His scientific achievements include publications in foreign and Polish journals and published in materials from national and international conferences. He is a member of the European Structural Integrity Society. He has participated in many research works, has technical expertise, and is an expert in assessing research projects in European Union programs.

Waldemar Kaszuwara

Waldemar Kaszuwara is currently a lecturer and researcher at Warsaw University of Technology, Faculty of Material Science and Engineering. He received his Ph.D. degree in 1994, professor of technical sciences since 2017. He specializes in technology of magnetic materials (Nd-Fe-B, Sm-Fe-N, Nd-Fe-Al, ferrites) and has more than 10 years of research experience in the field of ceramic-metal and polymer-metal graded composites forming by centrifugal casting.

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Abstract

Composites produced using the centrifugal gelcasting (CGC) method have an axially symmetrical shape with a hole in the axis. The top layer of the composite is rich in metallic components, while the inner layer is made entirely of ceramics. Between the outer and inner zones of such a pipe element, there is a gradual change in the share of the metallic phase. It was found that the local properties, measured along the structural gradient, depended on the content of Ni particles and changed accordingly in individual zones. The Ni content leads to reduced hardness and improved fracture toughness. The hardness of the external surface exceeds 10 GPa, with a crack resistance of 6.2 MPa·m^0.5, and in the inner layer, it is 19.6 GPa, with a crack resistance of 3.9 MPa·m^0.5. The samples have a comprehensive strength of 99.06 MPa.

Keywords

Gelcasting / Composites / Functionally graded material (FGM) / Centrifugal gelcasting (CGC) / Al₂O₃

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Justyna Zygmuntowicz, Joanna Tańska, Paulina Wiecińska, Paulina Piotrkiewicz, Katarzyna Konopka, Mikołaj Szafran, Marcin Wachowski, Janusz Torzewski, Waldemar Kaszuwara. Fabrication and characterization of Al₂O₃-Ni gradient composites for aggressive substance transport using centrifugal gelcasting. Advances in Manufacturing 1-17 DOI:10.1007/s40436-026-00603-1

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