Dispersing two-dimensional (2D) graphene sheets in 3D material matrix becomes a promising route to access the exceptional mechanical and electrical properties of individual graphene sheets in bulk quantities for macroscopic applications. However, this is highly restricted by the uncontrolled distribution and orientation of the graphene sheets in 3D structures as well as the weak graphene-matrix bonding and poor load transfer. Here, we propose a previously unreported avenue to embed ordered 2D graphene array into ceramics matrix, where the catastrophic fracture failure mode of brittle ceramics was transformed into stable crack propagation behavior with 250 to 500% improvement in the mechanical toughness. An unprecedentedly low dry sliding friction coefficient of 0.06 in bulk ceramics was obtained mainly due to the inhibition of the microcrack propagation by the ordered 2D graphene array. These unique and low-cost 2D graphene array/ceramic composites may find applications in severe environments with superior structural and functional properties.

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This paper proposes a simple reactive melt infiltration process to improve the mechanical properties of silicon carbide (SiC) ceramics. SiC matrix composites were infiltrated by Al–Si (10 wt.%)–xTi melts at 900 °C for 4 h. The effects of Ti addition on the microstructure and mechanical properties of the composites were investigated. The results showed that the three-point bending strength, fracture toughness (by single-edge notched beam test), and fracture toughness (by Vickers indentation method) of the SiC ceramics increased most by 34.3%, 48.5%, and 128.5%, respectively, following an infiltration with the Al–Si (10 wt.%)–Ti (15 wt.%) melt. A distinct white reaction layer mainly containing a Ti3Si(Al)C2 phase was formed on the surface of the composites infiltrated by Al alloys containing Ti. Ti–Al intermetallic compounds were scattered in the inner regions of the composites. With the increase in the Ti content (from 0 to 15 wt.%) in the Al alloy, the relative contents of Ti3Si(Al)C2 and Ti–Al intermetallic compounds increased. Compared with the fabricated composite infiltrated by an Al alloy without Ti, the fabricated composites infiltrated by Al alloys containing Ti showed improved overall mechanical properties owing to formation of higher relative content Ti3Si(Al)C2 phase and small amounts of Ti–Al intermetallic compounds.