Leveraging rapid sintering to retain metastable zirconia in copper

Abstract: Cermets combining metastable ceramics and ductile metals promise superior toughness and strength. However, retaining metastability often requires high-temperature sintering that coarsens microstructures and relaxes matrix constraint. Here we introduce an ultrafast high-temperature sintering (UHS) strategy to overcome this trade-off in zirconia-copper cermets. By applying Joule heating at around 100 degrees C per second to 900 degrees C with only a 20 second hold, we obtained cermets containing up to 50 weight percent of metastable austenite in zirconia at room temperature within a fine-grained and homogeneous microstructure. The rapid sintering kinetically favors semi-thermal austenite formation while suppressing copper grain growth and matrix relaxation, thereby stabilizing the high-temperature phase and simultaneously preserving microstructural refinement. This approach offers significant potential for copper-based composites in applications such as transformation toughening, self-healing, and crack detection.