Strength estimation of ceramic–metal joints with various interlayer thickness

ABSTRACT Residual stresses generated by the mismatch of thermal expansion coefficients of ceramics and metals affect the strength of ceramic–metal joints. An interlayer metal can be inserted between the ceramic and metal in order to relax this stress. An analysis was carried out of the residual stresses produced during joint‐cooling and in 4‐point bending tests. The effects of interlayer thickness on ceramic–metal joint strength were then studied by considering a superimposed stress distribution of the residual stress and the bending stress. Finally, joint strength was estimated from fracture mechanics and strength probability analysis by considering the residual stress distribution, defect size and position of pre‐existing defects in the ceramic parts. As a result of this study, we suggest an optimum material selection and interlayer thickness for ceramic–metal joint structures. This approach is generally suitable for the design of electrical and mechanical structures.