Carbon nanotubes-reinforced Ni foam interlayer for brazing SiO2-BN with Ti6Al4V alloy using TiZrNiCu brazing alloy

Brazing SiO₂-BN with Ti6Al4V is often associated with the problems of high residual stress and excessive Ti-based compounds formed. To overcome these problems, we report a new type interlayer of carbon nanotube (CNT) reinforced Ni foam fabricated by plasma enhanced chemical vapor deposition. The in-situ grown CNT are homogenously dispersed on 3D structure Ni foam, which could effectively avoid damage and agglomeration in the brazing seam. Result shows that Ni foam could consume excessive dissolved Ti, and CNT was beneficial for restricting the growth of phase, improving joining strength and releasing residual stress rapidly. The average shear strength of the joint brazed with CNT-Ni foam is about 50 MPa, and this value is about 5 times higher than that of joints brazed with pure TiZrNiCu. Further, a new simulated experiment was carried out innovatively to solving the difficulty of investigating interfacial behavior of CNT in brazing seam. Then the results clarify that integral structure of CNT can prevent the reaction with Ti. In situ growth of CNT on Ni foam could provide a way for introducing CNT into brazing seam without damaging structure of CNT.     

Effect of Ni foam on the microstructure and properties of AlN ceramic/Cu brazed joint

Aluminum nitride (AlN) ceramics and oxygen-free Cu were brazed with multilayer filler consisted of Ag-Cu-Ti +Ni foam. The microstructure and forming principle of AlN/Cu joints were studied and the influence of Ni foam on the joints was focused. The result shows that the composition of AlN/Cu joint was AlN/TiN/Ni₃Ti+Cu(s,s)+CuTi+Ni foam+Ag(s,s)/Cu. The joint strength was only 66.7 ± 3.7MPa with pure Ag-Cu-Ti solder and the fracture occurred inside AlN ceramics due to the residual stress. The foam nickel reacted with Ag-Cu-Ti filler metal to form Ni₃Ti during brazing process. Ni foam still retained the basic skeleton structure during brazing, and the mechanical capacity of AlN/Cu joint was enhanced significantly. The maximum shear strength of the brazed joint can reach 89.6 ± 4.5 MPa with .1 mm Ni foam, and the fracture position changed to the brazing filler. The result shows that nickel foam can reduce the residual thermal stress, and the mechanical properties of AlN/Cu joints were improved.     

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.     

Microstructure evolution and mechanical property of ZrC-SiC/Ti6Al4V joints brazed using Ti-15Cu-15Ni filler

ZrC-SiC ceramic and TC4 alloy were successfully brazed using a self-prepared Ti-15Cu-15Ni filler. The microstructure and mechanical property of the joints obtained at different brazing temperatures were investigated. The results indicated that Ti from the Ti-15Cu-15Ni and the TC4 reacted with the ZrC-SiC to form TiC phase adjacent to the ZrC-SiC ceramic. In the brazing seam, Ti₂(Ni, Cu) intermetallic compounds zone (IMCs Zone), Hypoeutectic Zone and Hypereutectoid Zone formed. The brazing temperature affected the dissolution of TC4 into the braze filler significantly, and then determined the microstructure of the joint. The formation of α-Ti in the brazing seam could decrease the hardness and the brittleness of the brazing seam, which was beneficial to the property of the brazed joint. The joint strength reached a maximum value of 43 MPa when the joint was brazed at 970 °C and cracks propagated in the ZrC-SiC substrate near the brazing seam.     

Graphite-reinforced AgCuTi/Cu foam composite filler to braze Al2O3 ceramic and 304 stainless steel

Al₂O₃ ceramic and 304 stainless steel were brazed with AgCuTi filler in this paper. Two kinds of composite filler were prepared by adding Cu foam and Cu foam covered with graphite (Gr-Cu foam) to relieve the residual stress of the joints. The effects of Cu foam pore size on the joints were investigated in detail, and the evolution mechanism of the joints was analyzed. Graphite-reinforced Cu foam was fabricated by spraying graphite for the first time. Results showed that the extremely low coefficient of thermal expansion of graphite and the good energy absorption performance of Cu foam were both conducive to reducing the thermal residual stress during the cooling process. Gr-Cu foam with pre-filled pores was used to solve the problems of structural dissolution of Cu foam and unfilled solder in Cu foam pores to a certain extent. And it played a key role in preventing the diffusion of metal atoms. The graphite on the surface of the Cu foam generated TiC in the brazing seam. The TiC and Cu foam promoted the formation of the TiCu strengthening phase. Furthermore, when the pore size of the Gr-Cu foam was 150 μm, the maximum shear strength of the joint was 246.84 MPa. This value was about 40% higher than that of Cu foam with the same pore size. The residual stresses of joint with and without graphite-reinforced were calculated, respectively, for both conditions. The reduction of residual stress was found after adding the graphite during brazing.     

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 property of ZrC-SiC ceramic and Ti6Al4V joint brazed with AgCuTi alloy

ZrC-SiC ceramic and TC4 alloy were brazed using AgCuTi alloy. The microstructure and mechanical property of the joints obtained at different brazing parameters were investigated and the reaction mechanism was analyzed. The results indicated that the Ti from the AgCuTi and TC4 reacted with the ZrC in the ceramic to form different shaped TiC crystals adjacent to the ZrC-SiC ceramic. With the increase of brazing temperature or extending of holding time, the dissolution of TC4 became vigorous and much Ti dissolved into the braze alloy. As a result, Ti reacted with the Cu from AgCuTi alloy to form a series of Cu-Ti compounds in the brazing seam due to the strong affinity between Cu and Ti. The Cu-Ti compounds made the hardness and brittleness of brazing seam increase, which deteriorated the property of the brazed joint. The maximum shear strength was 39 MPa obtained at 810 °C for 5 min.     

Interfacial microstructure and strengthening mechanism of BN-doped metal brazed Ti/SiO2-BN joints

Ag–Cu–Ti + BN composite filler was developed to braze SiO₂-BN ceramic and titanium. The effects of BN particles content on the microstructure and mechanical properties of the joints were investigated. The fine TiB whiskers and TiN particles were synthesized in the brazing seam by introducing BN particles. TiN–TiB₂ reaction layer formed adjacent to SiO₂-BN ceramic while Ti–Cu compound layer formed at Ti substrate. With the increase of BN content, more fine-grains formed in the joint and the reaction layer nearby the base materials became thinner. The hardness and modulus of the reaction phases were characterized by nanoindentations to reveal the plastic deformability of the brazing seam. The improvement of the joint strength was 340% with 3 wt.% BN addition. The joint strength was determined by the thermal expansion mismatch between the joined materials, plastic deformation in the brazing seam, and interfacial structure of the joint.     

C/SiC composite-Ti6Al4V joints brazed with negative thermal expansion ZrP2WO12 nanoparticle reinforced AgCu alloy

Brazing C/SiC composites to Ti6Al4V alloy is associated with the problem of high residual stress inducing low joining strength. To overcome this problem, negative thermal expansion Zr₂P₂WO₁₂ (ZWP) nanoparticles were introduced into AgCu brazing alloy to obtain robust C/SiC-Ti6Al4V joints. Microstructures and mechanical properties of the joints brazed with different ZWP contents were investigated. Results indicated that 3 wt% ZWP nanoparticles dispersed homogeneously among brazing seam and compatible with brazing alloy. The width of reaction layer at C/SiC side was reduced sharply. Meanwhile, the finite element analysis showed that residual stress was reduced by 52.9 MPa and stress concentration among reaction layer was eliminated. The average shear strength of the joints brazed with AgCu + 3 wt% ZWP increased to 146.2 MPa, which was 70.8% higher than that of joints brazed without ZWP.     

Brazing ZrO2 ceramic and TC4 alloy by novel WB reinforced Ag-Cu composite filler: Microstructure and properties

Residual stresses in ceramic-metal joints is the important factor for their reliable implementation in cutting-edge industries. Composite fillers is reported to be a promising approach to reduce the residual stresses. Until now, few experimental researches on the brazing of ZrO₂ ceramic and TC4 alloy using composite fillers have been reported. In this study, to release the residual stresses and improve the joints strength, novel WB reinforced Ag-Cu composite filler was fabricated to braze ZrO₂ ceramic and TC4 alloy. Scanning electron microscope (SEM), energy dispersive spectroscopy (EDS) and transmission electron microscopy (TEM) were applied for the analysis of microstructure and phases structure in the joints. The TiB whiskers and W particles were in situ synthesized via the reaction between active Ti and WB particles, and randomly distributed in the brazing seam. The effect of brazing temperature and WB content on interfacial microstructure and mechanical strength in the brazed joints were investigated. When brazed at 870 °C for 10 min, favorable microstructure reinforced by TiB whiskers and W particles in the brazing seam was achieved with 7.5 wt% WB addition in composite filler. The maximum average shear strength of the joints was 83.2 MPa, which about 59.4% increase over the joints without WB addition.     

In-Situ synthesized TiC nano-flakes reinforced C/C composite-Nb brazed joint

Brazing C/C composite to Nb is often associated with the problem of high residual stress, resulting in low-strength joints. To overcome these problems, here we carried out a simple polymer carbonization process to acquire uniform carbon-covered Cu foam composite interlayer, which was subsequently used for soundly brazing C/C composite and Nb with the assembly of C/C composite/Ag-Cu-Ti foil/C-Cu foam/Ag-Cu-Ti foil/Nb. Microstructure and mechanical properties of the joints were well investigated. The carbonization reacted with Ti elements, forming uniformly distributed in-situ TiC nano-flakes in the joint seam by virtue of the porous Cu foam skeleton. Results present that the in-situ TiC nano-flakes not only greatly reduced the thermal expansion coefficient but also effectively impeded the Cu solid solutions agglomeration. The average shear strength of the joint brazed with 3% C-Cu (wt.%) foam interlayer reached ～52.8 MPa with the brazing temperature of 880 °C for 10 min.     

Reactive brazing of silicon nitride to Invar alloy using Ni foam and AgCuTi intermediate layers

Silicon nitride (Si₃N₄) ceramic and Invar alloy have been brazed by using AgCuTi active filler and the Ni foam was added to further improve mechanical properties of joints in this study. The microstructure of Si₃N₄/Invar brazed joint changed obviously after adding Ni foam with different thickness. Ni foam reacted with the AgCuTi active filler during brazing, but it did not completely disappear and still maintained the basic frame structure after brazing. The average shear strength of the brazed joints with 0.2 mm Ni foam could reach 180 MPa, and their thermal cycle lifetime also improved significantly. The addition of Ni foam shifted the fracture location of joints from Si₃N₄ ceramic to brazing seam. These results indicated that the Ni foam could act as a buffer layer to reduce the residual thermal stress, and improve the mechanical properties of Si₃N₄/Invar joint.     

Interfacial microstructure and mechanical properties of TC4/Ti3SiC2 contact-reactive brazed joints using a Cu interlayer

Reliable contact-reactive brazed joints of TC4 alloy and Ti₃SiC₂ ceramic were obtained using a Cu interlayer. The interfacial microstructure of a TC4/Ti₃SiC₂ joint brazed at 920?°C for 10?min was TC4/Ti₂Cu +?α-Ti +?β-Ti/Ti₂Cu +?AlCu₂Ti +?Ti₅Si₃/Ti₅Si₃ +?Ti₅Si₄/Ti₃SiC₂. The interfacial microstructure and mechanical properties of TC4/Ti₃SiC₂ joints brazed at different temperatures were investigated. With increasing temperature, the shear strength of the brazed joints first increased and then decreased. The maximum shear strength was 132?±?8?MPa, and the corresponding fracture occurred along the Ti–Si reaction layer and the Ti₃SiC₂ substrate adjacent to the Ti–Si reaction layer. The microhardness test also demonstrated that the Ti–Si reaction layer possessed the highest microhardness, 812?±?22 HV. The Ti-Si reaction layer was the weakest part of the brazed joints. To eliminate the Ti-Si reaction layer and improve the mechanical properties of TC4/Ti₃SiC₂ brazed joints, a 40-μm Ni layer was plated on the surface of the Ti₃SiC₂ ceramic before brazing. The results showed that the Ti–Si reaction layer that formed adjacent to the Ti₃SiC₂ ceramic was thin and intermittent. Moreover, the interface between the Ti₃SiC₂ ceramic and the TC4 alloy became jagged. The shear strength of the TC4/nickel-plated Ti₃SiC₂ brazed joints improved to 148?±?8?MPa; the corresponding fracture occurred mainly in the Ti₃SiC₂ ceramic and only a small portion of the fracture occurred in the brazing seam.     

SiO2 migration mechanism at the joints of SiO2f/SiO2 composite brazed by bismuth glass

Joining is an indispensable process for expanding the application of ceramics and composites. Recently, glasses have been extensively explored for ceramic/composite joining owing to their unique functional needs. However, the difficulty in detecting amorphous materials and lack of enthalpy data make the interfacial reaction mechanism challenging to investigate. In this study, the interfacial reaction mechanism of joints of SiO_2f/SiO₂ composite-brazed bismuth glass was thoroughly explored. SiO₂ was dissolved from the matrix and used throughout the brazing process. In the initial stage, silica reacts with the brazing glass to form Bi₄(SiO₄)₃. Then, owing to the decomposition of Bi₄(SiO₄)₃, the silicate glass replaced the bismuth glass. Finally, some precipitation of SiO₂ occurred at the brazing seam owing to an entropy–enthalpy dominating mode. This study may instigate the design of brazing glasses for joining SiO_2f/SiO₂ composites.     

Enhanced mechanical properties and thermal cycling stability of Al2O3-4J42 joints brazed using Ag–Cu–Ti/Cu/Ag–Cu composite filler

This study investigates the mechanical properties and microstructure evolution of Al₂O₃-4J42 joints brazed using Ag–Cu–Ti (ACT) and Ag–Cu–Ti/Cu/Ag–Cu (ACTCA) fillers during thermal cycling from 0 °C to 500 °C. The reaction products between Al₂O₃ and brazing filler of these two types of joints are mostly composed of Ti–O compounds, Ti₄Cu₂O and Al-based compounds. Brittle intermetallic compounds (IMCs) are observed in ACT joints, but not found in ACTCA joints. The reaction layer in ACT joints becomes thinner and discontinuous with thermal cycles, while that in the ACTCA joints hardly changes. Besides, the stress-induced cracks occur within the Al₂O₃ ceramic near the Al₂O₃/filler interface in the ACT joints, but no crack is found in the ACTCA joints. The mechanical tests show that the ACTCA joints maintain at least 217%, 154% and 144% higher shear strength than the ACT joints at 0, 10 and 20 thermal cycles, respectively. The Cu interlayer with low yield strength releases stress through plastic deformation, meanwhile acts as a barrier to prevent elements diffusion and the formation of the brittle IMCs, thus improving the mechanical properties and thermal cycling stability of the joints.     

Microstructure and shear strength of ZrB2SiC/Ti6Al4V joint by TiCuZrNi with Cu foam

In this paper, brazing behaviors between ZrB₂SiC and Ti6Al4V by Cu foam interlayer were studied. The microstructure, formation mechanism, mechanical property and fracture surface of the joints were systematically studied. The results showed that the phases in the joints were α+β-Ti, TiCu, Ti₂Cu, Cu(s, s), TiC, TiB₂ and Ti₃SiC₂. An optimum shear strength reached up to 435??MPa?at a brazing temperature of 910?°C and holding time of 20?min. Such a shear strength was 90?MPa higher than the one without the Cu foam. The obtained high shear strength of joint was discussed from microstructure and residual stress. With the increase of brazing time, Cu(s,s) gradually disappeared and the content of Ti₂Cu intermetallic compound increased, which was harmful for the joint. Furthermore, the residual stress of joint with Cu foam was calculated to be 324?MPa, lower than the one without Cu foam interlayer.     

Effects of Cu interlayers on the microstructure and mechanical properties of Al2O3/AgCuTi/Kovar brazed joints

Al₂O₃ ceramic and Kovar alloy brazed joints were achieved using three types of Ag-based interlayers: a AgCuTi foil, a AgCuTi/Cu foil/AgCuTi multi-interlayer and a AgCuTi/Cu foam/AgCuTi multi-interlayer. The effects of the addition of Cu interlayers on the interfacial microstructure and mechanical properties of Al₂O₃/AgCuTi/Kovar brazed joints were investigated. When Kovar alloy and Al₂O₃ ceramic were brazed with 50 μm Cu foil at 900°C for 10 minutes, the Cu foil was completely dissolved in the liquid filler. A nearly continuous Cu layer remained in the joint when the thickness of the Cu foil reached 100 μm under the same brazing conditions. With the increase in Cu foil thickness, the thickness of Ti–O compounds + Ti₃Cu₃O reaction layer formed nearby the Al₂O₃ ceramic first increased and then remained the same. The Al₂O₃/Kovar joints brazed with 100 μm Cu foil at 900°C for 10 minutes showed a maximum shear strength of 138 MPa. A low brazing temperature was beneficial to maintain the original structure of the Cu foam. Furthermore, when the joints were brazed at 880°C for 10 minutes, the average shear strength of the Al₂O₃/AgCuTi/Cu foam/AgCuTi/Kovar joints was 140 MPa, which was 30 MPa higher than that of a single AgCuTi interlayer.     

Relief of the residual stresses in Si3N4/Invar joints by multi-layered braze structure – Experiments and simulation

An Ag–Cu–Ti+TiNp/Cu/Ag–Cu three-layered filler was designed to braze Si₃N₄ ceramic and Invar alloy. The effect of the Cu-foil thickness on the microstructure and the mechanical properties of the brazed joints was investigated. Compared with single-layer Ag–Cu–Ti+TiNp filler, the formation of Fe₂Ti and Ni₃Ti compounds is widely inhibited by using multi-layered filler. The shear strength of the brazed joint is 47.9% higher than that of joints brazed with single Ag–Cu–Ti+TiNp filler when a 200 μm thick Cu interlayer is used. A simplified unit cell model was designed to obtain the physical properties of the TiNp reinforced filler. The model provides the elastic modulus and yield stress that satisfy the Hashin–Shtrikman bounds and N. Ramakrishnan׳s equations, respectively. In the three-layered brazing, the finite element (FE) model shows that system residual stresses decrease significantly by increasing the thickness of Cu foil in the multi-layered system.     

Interfacial microstructure and mechanical properties of ZTA/ZTA joints brazed with Ni-Ti filler metal

The reliable brazing of the ZTA ceramic joints was successfully obtained using Ni-Ti filler metal. The microstructure and mechanical properties of the joints brazed at different temperatures were investigated. During the process of brazing, both Al₂O₃ and ZrO₂ in the ZTA reacted with the Ni-Ti filler, resulting in the formation of the AlNi₂Ti + Ni₂Ti₄O reaction layer adjacent to the ZTA substrate when brazed at 1350 °C for 30 min. NiTi and Ni₃Ti compounds precipitated at the center of brazing seam. When the brazing temperature increased from 1320 °C to 1380 °C, the thickness of AlNi₂Ti + Ni₂Ti₄O layer increased gradually. As the brazing temperature varied from 1400 °C to 1450 °C, TiO was formed adjacent to the ZTA substrate, along with the reduction of Ni₂Ti₄O. AlNi₂Ti distributed at the interface and center of brazing seam. The maximum shear strength of 152 MPa was obtained when brazed at 1420 °C for 30 min.     

Improvement for Ti3SiC2/Cu joint brazed using composite fillers with abnormal expansion ceramic particulates

Reducing the residual stresses and improving the mechanical strength of large-scale ceramic/metal brazing joints is an important problem that must be solved for its practical engineering application. Using composite filler with solid-state phase transformation ceramic particulates, it is theoretically feasible to relieve the residual stress and improve the mechanical properties of ceramic/metal brazed joints. In this study, Cu mesh, Ag–28Cu–2Ti (wt.%), and yttria-stabilized zirconia (0.6 mol.% YSZ solid-state phase transformation ceramic particulates) composite power fillers were used in the brazing of Ti₃SiC₂ ceramic and pure copper. The microstructure of joints and YSZ particulates in the interface was investigated and confirmed by scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), scanning transmission electron microscopy (STEM), and transmission electron microscopy (TEM). In addition, the effect of YSZ particulates content on the mechanical properties of joints was investigated and evaluated by the shear strength. The results show that the interfacial phases were mainly Ti₅Si₃, TiC, Ti_xCu, Ag (s, s), Cu (s, s), and YSZ particulates. Moreover, most of YSZ particulates undergo the solid-state phase transformation from tetragonal zirconia (t-ZrO₂) to monoclinic zirconia (m-ZrO₂) during the cooling process of brazing. The abnormal volume expansion of the solid-state phase transformation reduced the thermal mismatch between Ti₃SiC₂ ceramic and filler, thereby reducing the residual stress in the interface of joint. When using composite filler with 6 wt.% YSZ particulates, the shear strength of Ti₃SiC₂/Cu joint reached the maximum. The maximum average shear strength of the joints was 80.2 MPa, which was about 103.6% more than the joint without YSZ particulates.