Bioinspired design of silicon carbide–aluminum composites with tunable brick‐mortar structures via three‐dimensional printing and pressure infiltration

Overcoming the intrinsic trade‐off between strength and toughness remains a key challenge for metal matrix composites. Inspired by the “brick‐and‐mortar” (BM) architecture of natural nacre, this study presents a tunable structural design strategy that combines vat photopolymerization three‐dimensional printing with pressure‐assisted infiltration to fabricate silicon carbide‐aluminum (SiC–Al) composites with controlled brick aspect ratios and layered configurations. By synergistically regulating the surface oxidation of SiC particles and infiltration temperature, the formation of detrimental Al4C3 phases was effectively suppressed, resulting in a composite interfacial buffer layer composed of amorphous Al2O3 and Al that enhances interfacial bonding and thermal stress accommodation. Mechanical testing and finite element simulations demonstrate that an optimal brick aspect ratio promotes crack deflection and activates plastic energy dissipation in the Al matrix, leading to simultaneous improvements in strength and toughness. Notably, the BM composites exhibited ∼ 12% higher fracture toughness and ∼ 61% greater fracture energy compared to lamellar structures. This work highlights the critical role of structural geometry in achieving strength–toughness synergy, offering a promising approach for the bioinspired design of advanced metal–ceramic composites.