Joining of Cf/SiC composite to Ti-6Al-4V with (Ti-Zr-Cu-Ni)+Ti filler based on in-situ alloying concept

In this paper, a novel brazing process based on in-situ alloying concept was carried out to join C_f/SiC composite to TC4 alloy at 940 °C for 20 min. Mixed powders of Ti-Zr-Cu-Ni alloy and pure Ti metal were used as interlayer. In the process, Ti-Zr-Cu-Ni alloy melted and then dissolved pure Ti metal via liquid-solid reactions, achieving in-situ alloying of the interlayer. The interfacial microstructure and formation mechanism of the brazed joints were investigated. The effect of Ti powder content on the microstructure and the mechanical properties of joints were analyzed. The results showed that: the maximum lap-shear strength of the in-situ alloying brazed joints was 283±11 MPa when using (Ti-Zr-Cu-Ni)+40 vol% Ti composite filler, and this value was 79% higher than the mechanical strength when using Ti-Zr-Cu-Ni alone. A reaction layer of (Ti,Zr)C+Ti₅Si₃ formed near C_f/SiC composite side, while a diffusion layer of Ti₂Cu+Ti(s,s) formed near Ti-6Al-4V side. In the interlayer, lots of Ti(s,s) were distributed uniformly and few of Ti-Cu compounds were found, contributing to the plasticity of joints. Adding moderate Ti powder was beneficial for improving the interfacial reaction between C_f/SiC composite and filler material, which affected the lap-shear strength of joints.     

Effect of brazing parameters on microstructure and mechanical properties of Cf/SiC and Nb-1Zr joints brazed with Ti-Co-Nb filler alloy

Reliable brazing of carbon fiber reinforced SiC (C_f/SiC) composite to Nb-1Zr alloy was achieved by adopting a novel Ti45Co45Nb10 (at.%) filler alloy. The effects of brazing temperature (1270–1320 °C) and holding time (5–30 min) on the microstructure and mechanical properties of the joints were investigated. The results show that a continuous reaction layer (Ti,Nb)C was formed at the C_f/SiC/braze interface. A TiCo and Nb(s,s) eutectic structure was observed in the brazing seam, in which some CoNb₄Si phases were distributed. By increasing the brazing temperature or extending the holding time, the reaction layer became thicker and the amount of the CoNb₄Si increased. The optimized average shear strength of 242 MPa was obtained when the joints were brazed at 1280 °C for 10 min. The high temperature shear strength of the joints reached 202 MPa and 135 MPa at 800 °C and 1000 °C, respectively.     

Microstructure and mechanical properties of the C/C composite and Nb joints brazed with an active Ag-based filler metal

An active Ag-based filler metal, containing trace alloy elements of Al, Cu and Ti, was successfully applied to braze C/C composite and Nb. The microstructure and formation mechanism of the C/C composite and Nb brazed joint were investigated in this study. Moreover, the influence of brazing parameters on microstructural evolution and mechanical properties of brazed joints was evaluated. The typical interfacial microstructure of the joint obtained at 950 °C for 600 s was C/C/TiC + AlCu₂Ti/Ag(s, s) + AlCu₂Ti + particle Cu/AlCu₂Ti + AlCuTi + (Ti, Nb)₃Al + Nb(Ti)/Nb. The dispersive AlCu₂Ti phase was uniformly distributed in the Ag matrix, which was a beneficial structure for the brazed joint. The shear strength of the brazed joint was sensitive to the brazing temperature and holding time, which was closely related to the TiC layer bordering the C/C composite. The thickness of the TiC layer first increased as temperature increased to 950 °C, and then decreased when temperature reached 970 °C. The carbon fiber eroded by the filler at 970 °C entered to the brazing seam and reacted with Ti, resulting the reduction of the thickness of TiC, thus damaging the strength of the joint. With extension of holding time from 300 s to 1200 s, the interface reaction became more sufficient. Therefore, the thickness of the TiC layer increased. However, at 1200 s, the over-thick TiC broke the C/C substrate because of the mismatch of coefficient of thermal expansions. The maximum shear strength of the joint (950 °C/600 s) reached 55 MPa at room temperature and 35 MPa tested at 550 °C.     

Effects of random chopped short carbon fibers on microstructure and mechanical properties of joints for Cf/SiC composites by reaction bonding process

Random chopped short carbon fibers (C_sf)/phenol-formaldehyde resin (PF)/SiC powder mixtures are used as filler for the joining of C_f/SiC composites to obtain SiC interlayer at the joining region. The influences of C_sf on the microstructure and mechanical properties have been investigated. Research shows that the introduction of C_sf can improve the microstructure uniformity of the joint and reduce residual silicon content in the interlayer. The joint achieve a high flexural strength of 232?±?33?MPa as the carbon fiber content is 30?wt.%, which is similar to that of the C_f/SiC composites (220?±?21?MPa). The decrease in residual silicon content and the formation of nano-sized SiC particles are the main reasons for high joining strength.     

The use of a carbonized phenolic formaldehyde resin coated Ni foam as an interlayer to increase the high-temperature strength of C/C composite-Nb brazed joints

A novel carbonized phenolic formaldehyde resin (PF) resin-coated Ni foam was used as an interlayer for brazing carbon fiber reinforced carbon composites (C/C) and Nb using a Ti–Ni filler. At first, uniformly distributed carbonaceous laminae with different mass fractions on the Ni foam surface were acquired after the carbonization process by controlling the concentration of the PF solution. Afterwards, the obtained carbonaceous laminae covered Ni foam composite (C-Ni_f) was applied as an interlayer for brazing C/C and Nb via an assembly of C/C/Ti foil/Ni foil/C-Ni_f interlayer/Ti foil/Nb. The morphologies and microstructures of the carbonization product and the interfacial microstructures of the joints were investigated. The brazing mechanism has been elaborated in detail. With the help of the interconnected porous structure of the Ni foam, the distribution of the in-situ formed (Ti,Nb)₂Ni particles, (Ti,Nb)C ring reinforcements as well as the Nb solid solution were uniformly obtained throughout the brazing seam. As a result, the joint residual stress was effectively released and consequently, the joint shear strength at elevated temperature (1000 °C) reached up to 33 MPa, which is 4.5 times higher than the directly brazed joint without an interlayer.     

Interfacial microstructure and mechanical properties of zirconia ceramic and niobium joints vacuum brazed with two Ag-based active filler metals

Reliable brazing of a zirconia ceramic and pure niobium was achieved by using two Ag-based active filler metals, Ag-Cu-Ti and Ag-Cu-Ti+Mo. The effects of brazing temperature, holding time, and Mo content on the interfacial microstructure and mechanical properties of ZrO₂/Nb joints were investigated. Double reaction layers of TiO and Ti₃Cu₃O formed adjacent to the ZrO₂ ceramic, whereas TiCu₄+Ti₂Cu₃+TiCu compounds appeared in the brazing interlayer. With increasing brazing temperature and time, the thickness of the Ti₃Cu₃O layer increased with consumption of the TiO layer, and the total thickness of the reaction layers increased slightly. Meanwhile, the blocky Ti-Cu compounds in the brazing interlayer tended to accumulate and grow. This microstructural evolution and its formation mechanism are discussed. The maximum shear strength was 157 MPa when the joints were brazed with Ag-Cu-Ti at 900 °C for 10 min. The microstructure and bonding properties of the brazed joints were significantly improved when Mo particles were added into the Ag-Cu-Ti. The shear strength reached 310 MPa for joints brazed with 8.0 wt% Mo additive, which was 97% higher than that of joints brazed with single Ag-Cu-Ti filler metal.     

Brazing SiC ceramics and Zr with CoCrFeNiCuSn high entropy alloy

CoCrFeNiCuSn high-entropy alloy and Cu foam composite interlayer was used as a filler for the brazing of SiC ceramics and Zr. The microstructure and mechanical properties of the brazed joint at room temperature and high temperatures as well as the brazing mechanism were systematically investigated. The microstructure is adjusted by controlling the brazing temperature. The main phases in the joint were identified at different brazing temperatures to be a high-entropy alloy phase, α-Zr (s, s), Zr₂Cu, (Zr, Sn) and Zr(Cr, Fe)₂ Laves phase. The joint brazed at 1040 °C for 20 min exhibited a maximum shear strength of 221 MPa at room temperature and an average shear strength of 207 MPa at 600 °C. The room temperature and high temperature-strength obtained here are much higher than those obtained for joints brazed using a conventional filler. Owing to the high-entropy effect, the joint matrix is mainly composed of solid solution phase, which improves the strength and thermal stability of the joint. The existence of the hard Zr(Fe, Cr)₂ Laves phase and the soft α-Zr (s, s) phase in the joint significantly improves its strength and plasticity.     

Interfacial microstructure and performance of nano-diamond film/Ti-6Al-4V joint brazed with AgCuTi alloy

The CVD nano-diamond film and Ti-6Al-4V alloy were successfully brazed with AgCuTi active brazing filler. The interfacial microstructure was investigated by SEM, EDS, XRD and TEM. Typical interfacial microstructure of brazed joint was conformed as Ti-6Al-4V/diffusion layer/Ti₂Cu + TiCu + Ti₃Cu₄/Ag(s,s) + Cu(s,s) + Ti₂Cu₃/TiCu + TiC/nano-diamond film. The effects of brazing temperature on interfacial microstructure and mechanical properties of the brazed joints were analyzed. With the increasing brazing temperature, the thickness of reaction layers adjacent to Ti-6Al-4V substrate and nano-diamond film increased obviously. Moreover, the Ti₂Cu₃ phase coarsened and aggregated in brazing seam at higher temperature. The joint was formed by the diffusion and reactions between atoms, and the microstructure evolution of brazed joint was discussed. In addition, a slight graphitization of nano-diamond film occurred during brazing process, and the highest shear strength can reach 25 MPa when the joint was brazed at 880 °C for 10 min. Finally, the fracture positions and fractographs of brazed joints were also discussed.     

Interfacial microstructure and mechanical properties of porous-Si3N4 ceramic and TiAl alloy joints vacuum brazed with AgCu filler

Porous Si₃N₄ ceramic was firstly joined to TiAl alloy using an AgCu filler alloy. The effects of brazing temperature and holding time on the interfacial microstructure and mechanical properties of porous-Si₃N₄/AgCu/TiAl joints were studied. The typical interfacial microstructure of joints brazed at 880 °C for 15 min was TiAl/AlCu₂Ti/Ag-Cu eutectic/penetration layer (Ti₅Si₃+TiN, Si₃N₄, Ag (s, s), Cu (s, s))/porous-Si₃N₄. The penetration layer was formed firstly in the brazing process. With increasing brazing temperature and time, the thickness of the penetration layer increased. A large amount of element Ti was consumed in the penetration layer which suppressed the formation and growth of other intermetallic compounds. The penetration layer led the fracture to propagate in the porous Si₃N₄ ceramic substrate. The maximum shear strength was ~13.56 MPa.     

Control interfacial microstructure and improve mechanical properties of TC4-SiO2f/SiO2 joint by AgCuTi with Cu foam as interlayer

Brazing SiO_2f/SiO₂ ceramics to TC4 is often associated with the problems of excessive Ti from the dissolution of TC4 and high residual stress, which results in low-strength joints. To overcome these problems, here we put forward an effective method by introducing Cu foam as interlayer to obtain high-strength joints of SiO_2f/SiO₂-TC4. The effect of Cu foam on the microstructure and mechanical properties of brazed joints was investigated. Cu foam can consume Ti from TC4 and inhibit forming too many brittle compounds at the SiO_2f/SiO₂ side. Furthermore, Cu foam can react with Ti, forming the dispersed homogeneous distribution of fine-grained Ti-Cu compounds in the brazing seam, due to its unique 3D porous structure. The formation and distribution of fine-grained Ti-Cu compounds at the brazing seam could significantly help to reduce the residual stress and reinforce the mechanical properties of the joint. Maximum shear strength of 59.6 MPa is approached.     

Enhanced mechanical properties in Cf/LAS composite with yolk-shell structure interface

A new approach to improve the interfacial matching of carbon fiber-reinforced lithium-aluminum-silicon(C_f/LAS) composites is proposed, which is achieved by Ni nanoparticles catalyzing the formation of a tunable graphite layer on the surface of C_f. The interfacial structure between the composites can be effectively improved by tuning parameters such as Ni²⁺ content and sintering holding time, and ultimately, the mechanical properties of the composites can be improved. Interestingly, due to the introduction of Ni²⁺, a yolk-shell type graphite layer is formed between the C_f and LAS, and the bridging effect of the graphite layer improves interfacial bonding. The highest flexural strength (515 ± 30 MPa) and fracture toughness (14.7 ± 1.6 MPa·m^1/2) were obtained. Taking C_f/LAS as an example, the relationship between interfacial matching and mechanical properties of composites is systematically investigated and may provide a new idea for the improvement of mechanical properties of fiber-reinforced composites.     

Pressure-less joining of SiCf/SiC composites by Y2O3–Al2O3–SiO2 glass: Microstructure and properties

In this study, Y₂O₃–Al₂O₃–SiO₂ (YAS) glass was prepared from Y₂O₃, Al₂O₃, and SiO₂ micron powders. Thermal expansion coefficient of as-obtained YAS glass was about 3.9 × 10⁻⁶, matching-well with that of SiC_f/SiC composites. SiC_f/SiC composites were then brazed under pressure-less state by YAS glass and effects of brazing temperature on microstructures and properties of resulting joints were investigated. The results showed that glass powder in brazed seam sintered and precipitated yttrium disilicate, cristobalite, and mullite crystals after heat treatment. With the increase in temperature, joint layer gradually densified and got tightly bonded to SiC_f/SiC composite. The optimal brazing parameter was recorded as 1400 °C/30 min and shear strength of the joint was 51.7 MPa. Formation mechanism of glass-ceramic joints was proposed based on combined analysis of microstructure and fracture morphology of joints brazed at different temperatures. Thermal shock resistance testing of joints was also carried out, which depicted decline in shear strength with the increase of thermal shock times. The strength of the joint after three successive thermal shock cycles at 1200 °C was 35.6 MPa, equivalent to 69% of that without thermal shock.     

Low residual stress C/C composite-titanium alloy joints brazed by foam interlayer

Metallic foam was introduced as an interlayer to improve the performance of the brazed C/C composite-titanium alloy joint, and the interfacial microstructure and residual stress of the brazed joint were investigated. Compared with the brazed joint without foam, introducing foam interlayer could achieve the uniform bonding interface, and Ag-based solid solution (Ag(s,s)) became more dispersed and smaller in the center of the brazing seam. The thickness of reaction layer close to C/C composite side was less than 1 μm. Some Cu-based solid solution (Cu(s,s)) was detected, indicating that Cu foam still existed after brazing. The residual stress and its distribution calculated by finite element method (FEM), and the residual stress of the brazed joint decreased from 293 MPa to 228 MPa. The introduction of the foam interlayer could obtain homogeneous microstructure, change stress distribution, and improve mechanical properties of the brazed joints.     

Microstructure and mechanical properties of porous Si3N4/Invar joints brazed with Ag-Cu-Ti+Mo/Cu/Ag-Cu multi-layered composite filler

Ag-Cu-Ti/Cu/Ag-Cu multi-layered filler was successfully designed to braze porous Si₃N₄ and Invar alloy. To further reduce the CTE mismatch between the porous Si₃N₄ and brazing filler, Mo particles were introduced into Ag-Cu-Ti. The effects of the Mo addition on the microstructure and mechanical properties of the brazed joints were studied. The results showed that, the addition of Mo particles into Ag-Cu-Ti lowered the CTE mismatch and improved the joint strength to a certain degree. However, an excessive content was harmful. The Mo particles could absorb Ti at high temperature, causing Ti shortage in the reaction with the ceramic. When cooling down, the absorbed Ti was released. The released Ti could react with Cu to generate Cu-Ti phase. So, additional Ti was adopted in the brazing filler as a supplement. When the Ti content was 5 wt%, the reaction layer on the ceramic interface was too thin to transfer enough load. However, when it reached 15 wt%, the Cu interlayer dissolved completely and Fe-Ti and Ni-Ti phases appeared. The maximum joint shear strength (83 MPa) was obtained with 10 wt% Ti and 5 vol% Mo, which had exceeded 90% of the porous Si₃N₄ and was 56% higher than the joint brazed without Mo particles.     

Fabrication and properties of Cf/ZrC‐SiC‐based composites by an improved reactive melt infiltration

C_f/ZrC‐SiC composites with a density of 2.52 g/cm³ and a porosity of 1.68% were fabricated via reactive melt infiltration (RMI) of Si into nano‐porous C_f/ZrC‐C preforms. The nano‐porous C_f/ZrC‐C preforms were prepared through a colloid process, with a ZrC “protective coating” formed surrounding the carbon fibers. Consequently, highly dense C_f/ZrC‐SiC composites without evident fiber/interphase degradation were obtained. Moreover, abundant needle‐shaped ZrSi₂ grains were formed in the composites. Benefiting from this unique microstructure, flexural strength, and elastic modulus of the composites are as high as 380 MPa and 61 GPa, respectively, which are much higher than C_f/ZrC‐SiC composites prepared by conventional RMI.     

Characterization of carbon/carbon composite/Ti6Al4V joints brazed with graphene nanosheets strengthened AgCuTi filler

Carbon/carbon (C/C) composite and Ti6Al4V alloy (wt%) were successfully brazed with graphene nanosheets strengthened AgCuTi filler (AgCuTiG). Graphene nanosheets (GNSs) with low CTE and high strength were dispersed into AgCuTi filler by ball milling. The interfacial microstructure was systematically characterized by varieties of analytical means including transmission electron microscopy (TEM). Results show that typical interfacial microstructure of the joint brazed at 880 °C for 10 min is a layer structure consisting of (Ti6Al4V/diffusion layer/Ti2Cu + TiCu + Ti3Cu4 + TiCu4/GNSs + TiCu + TiC + Ag(s,s) + Cu(s,s)/TiC/C/C composite). The interfacial microstructure and mechanical properties of brazed joints changed significantly as temperature increased. High temperature promoted the growth of TiCu and TiC phases, which were attached to GNSs. Meanwhile, the diffusion layer and primary reaction layers thickened as temperature increased, while the thickness of brazing seam decreased. The maximum shear strength of 30.2 MPa was obtained for the joint brazed at 900 °C for 10 min. GNSs decreased the thickness of brittle reaction layers and promoted the formation of TiCu and TiC phases in brazing seam, which caused the strengthening effect and decreased the CTE mismatch of brazed joints. The fracture modes are also discussed in this paper.     

Mechanical properties and microstructure evolution of 3D Cf/SiBCN composites at elevated temperatures

3D C_f/SiBCN composites were fabricated by an efficient polymer impregnation and pyrolysis (PIP) method using liquid poly(methylvinyl)borosilazanes as precursor. Mechanical properties and microstructure evolution of the prepared 3D C_f/SiBCN composites at elevated temperatures in the range of 1500‐1700°C were investigated. As temperature increased from room temperature (371 ± 31 MPa, 31 ± 2 GPa) to 1500°C (316 ± 29 MPa, 27 ± 3 GPa), strength and elastic modulus of the composite decreased slightly, which degraded seriously as temperature further increased to 1600°C (92 ± 15 MPa, 12 ± 2 GPa) and 1700°C (84 ± 12 MPa, 11 ± 2GPa). To clarify the conversion of failure mechanisms, interfacial shear strength (IFSS) and microstructure evolution of the 3D C_f/SiBCN composites at different temperatures were investigated in detail. It reveals that the declines of the strength and changes of the IFSS of the composites are strongly related to the defects and SiC nano‐crystals formed in the composites at elevated temperatures.     

Brazing SiC ceramic using novel B4C reinforced Ag–Cu–Ti composite filler

The development of new composite fillers is crucial for joining ceramics or ceramics to metals because the composite fillers exhibit more advantages than traditional brazing filler metal. In this research, novel B₄C reinforced Ag–Cu–Ti composite filler was developed to braze SiC ceramics. The interfacial microstructure of the joints was characterized by scanning electron microscope (SEM), X-ray diffraction (XRD) and transmission electron microscopy (TEM). The effect of B₄C addition and brazing temperature on the microstructure evolution and mechanical properties of the joints was analyzed. The results revealed that TiB whisker and TiC particles were simultaneously synthesized in the Ag-based solid solution and Cu-based solid solution due to the addition of B₄C particles. As the brazing temperature increased, the thickness of Ti₃SiC₂+Ti₅Si₃ layers adjacent to SiC ceramic increased. Desirable microstructure similar to the metal matrix reinforced by TiB whisker and TiC particles could be obtained at brazing temperature of 950 °C. The maximum bending strength of 140 MPa was reached when the joints brazed at 950 °C for 10 min, which was 48 MPa (~52%) higher than that of the joints brazed using Ag–Cu–Ti filler.     

Ablation behavior and mechanism of Cf/SiBCN composites in plasma ablation flame

In this work, C_f/SiBCN composites are fabricated by an improved precursor infiltration and pyrolysis (PIP) approach. Ablation behavior of the C_f/SiBCN composites is investigated in plasma ablation flame at a heat flux of 4.02 MW m⁻², which provides a quasi-real hypersonic service environment at a temperature up to 2200°C. After ablation, the ablated surface is covered with oxidation products in the form of oxide layer, fibrous residues, or bubbles, which effectively isolates the sample surface from the plasma flame and inhibits the scouring of high-speed flame to the composites. As a result, the C_f/SiBCN composites present an excellent ablation-resistant property, with linear and mass recession rates as low as 0.0030 mm s⁻¹ and 0.0539 mg mm⁻² s⁻¹, respectively. It is also revealed that the material at ablation center undergoes crystallization and oxidation processes during ablation, while the ablation behavior at transition area and ablation fringe only contains oxidation process due to the local temperature difference. Si₃N₄ and SiC grains are precipitated from amorphous SiBCN matrix during the crystallization process, and the oxidation process mainly involves the oxidation of carbon fiber and SiBCN matrix, etc.     

Microstructures and tribological behaviors of Cf/C-SiC composites tailored by Cu and Fe-Si matrices

Ternary Cu-Fe-Si alloy were applied to modify tribological behavior of carbon fiber/carbon-silicon carbide (C_f/C-SiC) composites by reactive melt infiltration. Microstructures, physical properties and tribological properties on a full-scale train brake test rig of the modified composites were studied. Results indicate that both Cu and Fe-Si alloy as matrices lead to significantly enhanced thermal conductivity and compressive strength for C_f/C-SiC composites. Moreover, the average friction coefficient of the modified composites is between 0.25 and 0.55, which is higher than that of copper metal matrix composites. In addition, the average volume wear rate of the modified composites is only 0.168 cm³/MJ. The C_f/C-SiC composites modified by Cu and Fe-Si alloy with improved physical properties and tribological properties meet the technical requirement and show high application potential in express train brake systems.