Research Progress in Ceramic–Metal Composites: Designing Interface Structures for High Mechanical Performance

Abstract Ceramic–metal composites possess exceptional hardness and wear resistance, as well as high strength and ductility, rendering them highly promising for a wide range of applications. However, the performance of these composites can be significantly restricted by weak interfacial bonding, leading to crack formation at the interfaces; and ultimately, material failure. Therefore, poor interfacial bonding between ceramics and metals is a critical factor limiting the performance. Interfacial bonding strength can be enhanced by regulating the interface structure, which in turn, improves mechanical property. This review focuses on how to design strong interfacial structures in ceramic–metal composites, with particular emphasis on alumina ceramic–metal composites. It seeks to analyze the categorization of interfacial structures, design principles, and strategies for their formation, and examines the impact of interfacial bonding strength on the mechanical properties. Finally, it discusses the regulation of interfacial reactions, optimization of interface structures, integration of various interface designs, improvements in manufacturing technology, and the use of theoretical calculations to enhance interfacial bonding strength.