Increasing both strength and toughness in ceramic-matrix composites via bioinspired porous interphases

Ceramic-matrix composites face a persistent challenge: the trade-off between strength and toughness. Inspired by the mineral bridge architecture of nacre, we propose a reverse interphase design that contrasts with conventional dense-laminar pyrolytic carbon given the active incorporation of nanopores. Multiscale characterization and simulations reveal a dual reinforcement mechanism: nanopores reduce the interfacial debonding strength and induce crack deflection that protects fibers from brittle fracture. Meanwhile, the resulting rough fracture paths enhance interfacial frictional stress and load transfer, thereby improving the matrix bearing capacity and energy dissipation. This asymmetric modulation of interfacial properties simultaneously preserves fiber integrity and maximizes energy dissipation. The resulting single-tow Cf/SiC composites exhibit 903 MPa tensile strength, which is 38% higher than that of conventional designs, and a 1.8-fold increase in fracture energy. The interphase-enabled mechanisms identified here are intrinsically scalable, with their effectiveness further demonstrated in architectured ceramic-matrix composites. This work demonstrates a shift from empirical optimization toward theory-driven interface design and establishes a viable route to overcome the classical strength–toughness dilemma in structural composites. Ceramic composites are prone to breaking. Here, authors propose a bioinspired porous interphase that guides crack deflection and growth, coupling weak debonding with high friction to enhance load transfer, energy dissipation, strength and toughness.