Seamless joining of silicon carbide ceramics through an sacrificial interlayer of Dy3Si2C2

A ternary carbide Dy₃Si₂C₂ coating was fabricated on the surface of SiC through a molten salt technique. Using the Dy₃Si₂C₂ coating as the joining interlayer, seamless joining of SiC ceramic was achieved at temperature as low as 1500 °C. Phase diagram calculation indicates that seamless joining was achieved by the formation of liquid phase at the interface between Dy₃Si₂C₂ and SiC, which was squeezed out under pressure and continuously consumed by the joining interlayer. This work implies the great potential of the family of ternary rare-earth metal carbide Re₃Si₂C₂ (Re = Y, La-Nd) as the sacrificial interlayer for high-quality SiC joining.     

Diffusion bonding of transparent ceramics by spark plasma sintering (SPS) complemented by hot isostatic pressing (HIP)

Diffusion bonding is a viable technique for fabricating larger parts or composite transparent ceramics. Spark plasma sintering (SPS) and hot isostatic pressing (HIP) allow for simultaneous application of high temperature and pressure, making them suitable for bonding various materials, including transparent ceramics. In this study, we demonstrated the combined use of SPS followed by HIP for successful diffusion bonding of transparent MgAl₂O₄ (spinel) and Y₃Al₅O₁₂ (YAG) ceramics. The YAG samples had superior surface quality and were adequately bonded using SPS alone, while rougher spinel samples showed inadequate bonding initially due to insufficient surface contact. However, subsequent HIP treatment effectively closed the voids at the interface and promoted grain growth across the joint, resulting in a strong seamless bond. The combination of SPS and HIP, as a two-step process, holds promise for diffusion bonding of ceramics and offers a potential solution for compensating surface quality issues in the bonded parts.     

Joining of Al2O3 ceramic to Cu using refractory metal foil

Joining of Al₂O₃ ceramic to Cu has been conducted with Ag-26.7Cu-4.5Ti braze and refractory metal (W or Ta) foil. The interfacial microstructure in the joint with W foil is similar to that with Ta foil. The joining region in the joint consists of a reaction zone, braze zone I, refractory metal layer and braze zone II. The reaction zone of Cu₃Ti₃O with a thickness of about 5 μm develops close to Al₂O₃ side due to the reactions of Ti and Cu in the braze with Al₂O₃ substrate. The braze zones I and II are mainly composed of Ag- and Cu-based solid solutions. For the joint with W foil, the adsorption of Ti at the braze/W interfaces followed by the Ti diffusion into W foil occurs, whilst slight dissolution and diffusion of Ta into the brazes take place in the joint with Ta foil. The average shear strengths of joints with W and Ta foils are much higher than those without refractory metal foil, indicating the contribution of the refractory metal foil to the improvement of joint mechanical strength. Introduction of refractory metal foil in Al₂O₃/Cu joining is beneficial for the shift of joint residual stress distribution and the decrease of stress concentration in the joint since the coefficient of thermal expansion (CTE) of refractory metal layer approximately approaches that of Al₂O₃. Furthermore, a slight thickness increase of the Cu₃Ti₃O reaction zone in the joint with refractory metal foil may also give rise to the joint strength promotion.     

Joining of alumina using magnesium- or calcium-aluminosilicate glass–ceramic fillers

Magnesium- and calcium-aluminosilicate (MAS and CAS) glass–ceramics were used to join alumina with six different compositions. The fillers were applied onto the alumina by screen-printing, and then joining was performed slightly below and above the filler melting temperature (T_m). The evolution of various intermediate compounds upon heat treatment between the filler itself and at the joining interface was compared. MgAl₂O₄ and CaO·6Al₂O₃ was the main crystalline phase presented at the joining interface for the MAS and CAS system, respectively, while more intermediate compounds were observed when only filler was heat-treated. The formation of MgAl₂O₄ and CaO·6Al₂O₃ was attributed to the diffusion of Al ions from the alumina base, which is desirable for obtaining a sound joint due to the similar coefficient of thermal expansion to the base alumina. The maximum joint strength of 250 ± 41 and 301 ± 48 MPa was obtained for MAS and CAS filler system, respectively, after joining at T ≥ T_m due to complete interfacial wetting.     

Surface modification of SiC to improve joint strength via a Corona plasma treatment

The high mechanical and chemical properties of SiC make it difficult to texture and modify its surface using such conventional methods as mechanical machining and wet etching. Among possible alternative strategies, Atmospheric Pressure Plasmas (APPs) could be used, cutting cost and time, but much still has to be understood about their feasibility for the surface treatment of ceramic materials.In this work, the effectiveness of a commercial corona discharge system in modifying the surface of SiC has been evaluated, focusing on its positive effect on the joint strength of adhesively bonded plasma-treated SiC.The objective of the study has been to observe the surface changes, in terms of chemical composition and texture, that take place as a result of exposure to corona plasma and to compare the obtained results with previous studies on laser and low-pressure plasma textured SiC samples. These very first results, derived from characterization and mechanical testing, suggest that this approach could be a promising alternative.     

Torsional behaviour of glass-joined,laser-processed Crofer 22 APU interconnect: Unravelling the effect of surface roughness on the shear strength

Glass-to-metal interfaces play a crucial role in the robustness and the mechanical integrity of solid oxide cells, and it is well known that a sound interface improves the mechanical reliability of the whole stack. The present work focuses on the torsional behaviour of hourglass-shaped Crofer 22 APU stainless steel joined by a glass sealant specifically designed for this application.Specific focus was given to the Crofer surface modification by laser processing, namely, the laser fluence was varied to find suitable roughness parameters; a laser fluence of 14.1 J cm^?2, leading to a Crofer surface roughness of about 4.6 μm, was selected as the optimal Crofer surface processing before the joining process.The torsional shear strength of glass-joined as-received Crofer was measured as 24 ± 7 MPa with mainly adhesive fracture mode, with failure jumping from one interface to the other, while the laser-processed Crofer gave 32 ± 5 MPa with cohesive failure. The approximate 30% increase of torsional shear strength is due to the mechanical interlocking effect given by glass infiltration inside the laser-induced protrusions on Crofer as evidenced by SEM/EDS on cross-sections and fracture surfaces after torsion tests.     

Entwicklung des Reibnietens als neues Fügeverfahren für Kunststoff und Leichtbaulegierungen

Development of FricRiveting as a new joining technique for polymer and lightweight alloys The increasing demand on environmental consciousness, cost savings and high performance end products has been guiding scientists and engineers to a constant development of new materials and technologies. This class of lightweight structures are specially used in industrial fields such as transportation and modern civil engineering. Currently available joining methods for polymer‐metal structures (adhesive bonding and mechanical fastening) are usually application‐specific, presenting high operational costs, limited mechanical performance or are not environmental friendly. A new Friction Riveting technique for polymeric‐metallic joints was developed, demonstrated and characterized in this work, as an alternative, reliable, environmental compatible and economically viable spot joining process. In the simplest process variant a rotating cylindrical metallic rivet is inserted in one or more thermoplastic base plates. The high rotation speed and pressure increase friction and heat is generated. When the preset time is achieved the temperature highly increases and the rivet tip plasticizes. At this point rotation is decelerated and the axial pressure increased, so the plasticized rivet tip becomes deformed; after cooling it becomes anchored in the polymeric base plate. In this work case‐study joints on commercially available polyetherimide (PEI) and aluminium 2024‐T351 (Al‐Cu‐Mg alloy) were chosen for demonstrating proposed theories and mechanisms of FricRiveting. Sound friction riveted point‐on‐plate and single‐rivet overlap joints with elevated joint efficiencies in terms of base materials strength were obtained (tensile joint efficiencies of about 97 % of the rivet strength and shear joint efficiencies of about 70 % of the polymer strength) through tensile and lap shear testing at room temperature. Finally, the microstructural changes and properties were described for this case‐study joint. The feasibility of FricRiveting was demonstrated in this work by the presented technical and scientific results. From this work it can be suggested that FricRiveting has the potential to be established as a reliable, simple, cost effective and environmental friendly joining technique for polymer‐metal components.     

装配式凸轮轴制造技术现状与发展趋势

本文论述了装配式凸轮轴的发展背景及其技术优势。分析了装配式凸轮轴的连接方法和优缺点。介绍了装配式凸轮轴的制造技术，使用范围及国内外的生产技术现状和发展趋势。     

Joining of Cf/SiC composite with a Cu–Au–Pd–V brazing filler and interfacial reactions

A new Cu–Au–Pd–V filler alloy was designed for the joining of C_f/SiC composite. Its wettability on the composite was studied with the sessile drop method. After heating at 1473 K for 10 min the filler alloy showed a low contact angle of 5°. The interfacial reactions under the brazing condition of 1443 K/10 min resulted in the formation of VC_0.75 reaction band at the surface of the composite, and the microstructure in the central part of the joint is composed of Cu(Au, Pd) solid solution and Pd₂Si compound. The average three-point bend strength of the C_f/SiC–C_f/SiC joints at room temperature is 135 MPa. The joints also exhibit stable strengths at high temperatures of 873–1073 K. The presence of refractory Pd₂Si compound within the Cu(Au, Pd) solid solution matrix throughout the joint should contribute to the stable high-temperature property.     

Ball impact cladding of metals with dissimilar metallic foils

Ball impact cladding is a process in which solid-state welding of a foil and substrate is carried out in a vibration mill. The principle of the process is that a substrate and foil are fixed at the top of a vibration chamber. During the subsequent mechano-activation process, the materials are subjected to high-energy collision with balls. As a ball collides with the surface, the foil is cold welded to the substrate. This is a simple and effective method for joining materials, and it also results in the formation of nanostructures. For example, the welding of Cu and Al foils to Al, Ti, and steel substrates has been attempted. Diffusion and plastic flow of materials under ball collisions were the main joining mechanisms contributing to welding. Under the ball collisions a nanograin structure was formed across the foil and at the interface of the substrates. The cladding foils had a good adhesion to substrates.