Structure-interface-performance relationships of ceramic fillers in polymer, metal, and ceramic matrix composites: A critical review

Ceramic fillers are essential for improving the mechanical, thermal, electrical, and multifunctional properties of modern composite materials. This critical analysis systematically analyzes the impact of commonly utilized ceramic fillers-alumina, silicon carbide, barium titanate, and cobalt ferrite on polymer, metal, and ceramic matrix composites via a cohesive structure-interface-performance framework. The review clarifies essential enhancements and operational mechanisms resulting from filler properties, interfacial interactions, and microstructural development, focusing specifically on tensile strength, wear resistance, dielectric properties, magnetic behavior, and thermal stability. A comparative analysis of primary fabrication methods, such as powder metallurgy, sol-gel processing, melt blending, and hot pressing, is conducted regarding filler dispersion, interfacial bonding, process scalability, and industrial significance. This review thoroughly examines the application prospects in aircraft, military, electronic packaging, sensing technologies, energy storage, and biomedical engineering. Current problems include nanoparticle aggregation, interfacial incompatibility, and elevated processing costs, alongside rising prospects in additive manufacturing and multifunctional smart composites. This review offers design-focused insights to inform the advancement of next-generation ceramic-filled composite systems for sophisticated engineering applications.