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Zirconia toughened alumina particles (ZTAp)/high chromium cast iron (HCCI) matrix honeycomb composites were successfully prepared by a non-pressure infiltration casting process. This paper systematically investigates the effect of pore size (6mm, 8mm, 10mm, 12mm) on the compression resistance of honeycomb structure under the same wall thickness condition. Through the simulation software Ansys Workbench and compression performance test, it was found that the fracture location of the composite material occurred mainly at the interface location between the composite area and the matrix area during the compression process of the specimen, and the actual compression results were consistent with the simulation results. The compression performance tends to increase gradually with the increase of the honeycomb pore size, and the optimal compression resistance is reached when the pore size is 12 mm. This optimum performance is attributed to the fact that the reinforcement mechanism of the composite depends not only on the load sharing of the reinforcing particles, but also on the strength of the matrix.

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In order to reduce the thermal stress in high chromium cast iron (HCCI) matrix composites reinforced by zirconia toughened alumina (ZTA) ceramic particles, finite element simulation is performed to optimize the geometrical configuration of ceramics perform. The previous model simplifies the overall structure of the ceramic particle preform and adds boundary conditions to simulate the particles, which will cause uncontrollable error in the results. In this work, the equivalent grain models are used to describe the actual preform, making the simulation results closer to the actual experimental results. The solidification process of composite material is simulated and the infiltration between molten iron and ceramic particles was realized. Thermal stress in solidification process and compression stress distribution are obtained. The results show that adding 10mm round holes on the preform can improve the performance of the composite, which is helpful to prevent the cracks and increases the plasticity of the material.