陶瓷材料电场辅助连接技术研究现状及发展趋势

doi:10.15541/jim20220400

摘要/Abstract

摘要：

陶瓷材料因具有良好的机械性能、抗腐蚀性、耐高温性及抗氧化性等, 被广泛应用于航空航天、医疗、能源交通等领域, 陶瓷材料自身及其与金属材料的连接技术对于实际工程应用具有重要意义。由于部分陶瓷材料与电场的特殊作用机理, 将外加电场应用于陶瓷材料的连接技术中, 可以获得多种普通连接技术所不具备的优势, 如连接温度较低和连接时间较短等, 这就催生了新型陶瓷材料电场辅助连接技术。本文着重梳理了陶瓷及陶瓷基复合材料电场辅助连接技术的研究现状, 对近年来电场辅助连接技术的研究进展进行了综述, 重点介绍了电场辅助扩散连接(Electric field-assisted diffusion bonding, FDB) 技术、放电等离子体烧结 (Spark plasma sintering, SPS)连接技术以及新型低温快速闪连接(Flash joining, FJ) 技术的连接机理、典型界面微观结构、接头强度及影响因素等, 阐述了不同电场辅助连接技术的适用范围和局限性, 并对陶瓷材料电场辅助连接技术的发展进行了展望。

关键词: 陶瓷, 电场辅助, 电场辅助扩散连接, SPS连接, 闪连接, 综述

Abstract:

Ceramic materials are widely used in aerospace, medicine and energy transportation concerned for their excellent over-all mechanical and chemical properties, such as corrosion resistance, high temperature resistance and oxidation resistance. Especially, joining ceramic materials themselves and connecting them with metals are of great significance for the practical engineering applications. Compared with traditional joining technology, electric-assisted joining technology possesses a variety of advantages, such as low temperature and short time, owing to the special influence of the electric field on some ceramic materials. This paper focuses on the development of the electric-field assisted joining technologies of ceramics and ceramic matrix composites, and summarizes their research status in recent years. From the views of joining mechanism, typical interface microstructure and joint strength and influencing factors, the electric-field assisted diffusion bonding (FDB), spark plasma sintering (SPS) joining, and the new low-temperature rapid flash joining (FJ) are reviewed. Moreover, the applicable scope and limitations of different electric-field assisted joining technologies are expounded. In addition, the development trend of the electric-field assisted joining technology of ceramic materials is prospected.

Key words: ceramics, electric field, electric field-assisted diffusion bonding, SPS joining, flash joining, review

中图分类号:

TQ174

刘岩, 张珂颖, 李天宇, 周菠, 刘学建, 黄政仁. 陶瓷材料电场辅助连接技术研究现状及发展趋势[J]. 无机材料学报, 2023, 38(2): 113-124.

LIU Yan, ZHANG Keying, LI Tianyu, ZHOU Bo, LIU Xuejian, HUANG Zhengren. Electric-field Assisted Joining Technology for the Ceramics Materials: Current Status and Development Trend[J]. Journal of Inorganic Materials, 2023, 38(2): 113-124.

图/表 20

参考文献 77

[1]	LI Z R, GU W, FENG J C. Research status of ceramic and metal joining. Welding, 2008(3): 55.
[2]	SHI K Q, LI M, ZHU D D, et al. Research progress of brazing between ceramic and metal. Thermal processing, 2021, 50(13): 7.
[3]	JIAO R B, RONG S F, LI H B, et al. Current situation and prospect of advanced ceramics and metal connections. Foshan Ceramics, 2018, 28(3): 6.
[4]	CONG S S. State-of-the-art bonding methods for ceramics and metals. Bonding, 1983(3): 21.
[5]	FU W, SONG X G, ZHAO Y X, et al. Indirect brazing of Al₂O₃ ceramics and copper. Journal of Welding, 2015, 36(6): 27.
[6]	LIU H J, LI Z R, FENG J C, et al. Vacuum brazing of SiC ceramics and TiAl alloys. Welding, 1999(3): 7.
[7]	WANG Q, CHEN G Q, WANG K, et al. Microstructural evolution and growth kinetics of interfacial compounds in TiAl/Ti₃SiC₂ diffusion bonding joints. Materials Science and Engineering A-Structural Materials Properties Microstructure and Processing, 2019, 756: 149. DOI URL
[8]	ZHANG C G, QIAO G J, JIN Z H. Active brazing of pure alumina to Kovar alloy based on the partial transient liquid phase (PTLP) technique with Ni-Ti interlayer. Journal of the European Ceramic Society, 2002, 22(13): 2181. DOI URL
[9]	LI S J, ZHOU Y, DUAN H P, et al. Joining of SiC ceramic to Ni-based superalloy with functionally gradient material fillers and a tungsten intermediate layer. Journal of Materials Science, 2003, 38(19): 4065. DOI URL
[10]	ESSA A A, BAHRANI A S. The friction joining of ceramics to metals. Journal of Materials Processing Technology, 1991, 26(2): 133. DOI URL
[11]	DOEHLER F, ZSCHECKEL T, KASCH S, et al. A glass in the CaO/MgO/Al₂O₃/SiO₂ system for the rapid laser sealing of alumina. Ceramics International, 2017, 43(5): 4302. DOI URL
[12]	RABIN B H. Joining of silicon carbide/silicon carbide composites and dense silicon carbide using combustion reactions in the titanium-carbon-nickel system. Journal of the American Ceramic Society, 1992, 75(1): 131. DOI URL
[13]	FERNIE J A, DREW R A L, KNOWLES K M. Joining of engineering ceramics. International Materials Reviews, 2009, 54(5): 283. DOI URL
[14]	JING W, ZHANG H. Influence of packaging technology on performance of power semiconductor modules. Power Electronics Technology, 2018, 52(8): 1.
[15]	LIU F J, DU Z L, CHEN S P, et al. Effect of electric field on the structure and mechanical properties of AZ₃₁B/Al diffusion bonding interface. Weapon Materials Science and Engineering, 2009, 32(5): 18.
[16]	WALLIS G, POMERANTZ D I. Field assisted glass-metal sealing. Journal of Applied Physics, 1969, 40(10): 3946. DOI URL
[17]	BYEON S C, HONG K S. Electric field assisted bonding of ceramics. Materials Science and Engineering A-Structural Materials Properties Microstructure and Processing, 2000, 287(2): 159. DOI URL
[18]	MUNIR Z A, ANSELMI-TAMBURINI U, OHYANAGI M. The effect of electric field and pressure on the synthesis and consolidation of materials: a review of the spark plasma sintering method. Journal of Materials Science, 2006, 41(3): 763. DOI URL
[19]	DONG H, LI S, TENG Y, et al. Joining of SiC ceramic-based materials with ternary carbide Ti₃SiC₂. Materials Science and Engineering: B, 2011, 176(1): 60. DOI URL
[20]	FITRIANI P, SEPTIADI A, HYUK J D, et al. Joining of SiC monoliths using a thin MAX phase tape and the elimination of joining layer by solid-state diffusion. Journal of the European Ceramic Society, 2018, 38(10): 3433. DOI URL
[21]	TATARKO P, CASALEGNO V, HU C, et al. Joining of CVD-SiC coated and uncoated fibre reinforced ceramic matrix composites with pre-sintered Ti₃SiC₂ MAX phase using Spark Plasma Sintering. Journal of the European Ceramic Society, 2016, 36(16): 3957. DOI URL
[22]	GRASSO S, TATARKO P, RIZZO S, et al. Joining of β-SiC by spark plasma sintering. Journal of the European Ceramic Society, 2014, 34(7): 1681. DOI URL
[23]	ZHOU X, HAN Y H, SHEN X, et al. Fast joining SiC ceramics with Ti₃SiC₂ tape film by electric field-assisted sintering technology. Journal of Nuclear Materials, 2015, 466: 322 DOI URL
[24]	XIA J, REN K, WANG Y. One-second flash joining of zirconia ceramic by an electric field at low temperatures. Scripta Materialia, 2019, 165: 34. DOI URL
[25]	KNOWLES K M, VAN HELVOORT A T J. Anodic bonding. International Materials Reviews, 2006, 51(5): 273. DOI URL
[26]	PAN R. Study on technology and mechanism of electric-assisted diffusion bonding of alumina ceramic to Ti. Harbin: Master Thesis of Harbin Institute of Technology, 2013.
[27]	DUNN B. Field-assisted bonding of beta-alumina to metals. Journal of the American Ceramic Society, 1979, 62(11/12): 545. DOI URL
[28]	BYEON S C, BYUN T Y, HONG K S. Bonding between single- crystal manganese-zinc ferrites using electric field. Journal of Materials Research, 1998, 13(11): 3191. DOI URL
[29]	BYEON S C, JE H J, HONG K S. Direct current-induced bonding between single- and polycrystalline manganese-zinc ferrites. IEEE Transactions on Magnetics, 2000, 36(1): 371. DOI URL
[30]	LU F H, DIECKMANN R. Point defects and cation tracer diffusion in (Co, Fe, Mn)_3-_δO₄ spinels: I. Mixed spinels (Co_xFe₂_yMn_y)_3-_δO₄. Solid State Ionics, 1992, 53-56: 290. DOI URL
[31]	LU F H, DIECKMANN R. Point defects and cation tracer diffusion in (Co, Fe, Mn)_3-δO₄ spinels: II. Mixed spinels (Co_xFe_zMn₂_z)_3-δO₄. Solid State Ionics, 1993, 59(1): 71. DOI URL
[32]	ARATA Y, OHMORI A, SANO A. Interfacial phenomena during field assisted bonding of zirconia to metals. Transactions of JWRI, 1986, 15(2): 387.
[33]	YANG B, SHEN P, YU L T, et al. Electrochemically-driven direct joining of Ni and ZrO₂. Scripta Materialia, 2017, 141: 41. DOI URL
[34]	PAN R, WANG Q, SUN D, et al. Effects of electric field on interfacial microstructure and shear strength of diffusion bonded α-Al₂O₃/Ti joints. Journal of the European Ceramic Society, 2015, 35(1): 219. DOI URL
[35]	DONG P, WANG Z, WANG W, et al. Understanding the spark plasma sintering from the view of materials joining. Scripta Materialia, 2016, 123: 118. DOI URL
[36]	MAMEDOV V. Spark plasma sintering as advanced PM sintering method. Powder Metallurgy, 2002, 45(4): 322. DOI URL
[37]	SHEN Z, JOHNSSON M, ZHAO Z, et al. Spark plasma sintering of alumina. Journal of the American Ceramic Society, 2002, 85(8): 1921. DOI URL
[38]	GUILLON O, GONZALEZ-JULIAN J, DARGATZ B, et al. Field-assisted sintering technology/Spark plasma sintering: mechanisms, materials, and technology developments. Advanced Engineering Materials, 2014, 16(7): 830. DOI URL
[39]	LI H, KOYANAGI T, ANG C, et al. Electric current-assisted direct joining of silicon carbide. Journal of the European Ceramic Society, 2021, 41(5): 3072. DOI URL
[40]	RIZZO S, GRASSO S, SALVO M, et al. Joining of C/SiC composites by spark plasma sintering technique. Journal of the European Ceramic Society, 2014, 34(4): 903. DOI URL
[41]	SHEN L, XUE J M, BARSOUM M W, et al. Rapid bonding of Ti₃SiC₂ and Ti₃AlC₂ by pulsed electrical current heating. Journal of the American Ceramic Society, 2014, 97(12): 3721. DOI URL
[42]	ZHOU X, SHI L-K, ZOU S, et al. Fast seamless joining of SiC_w/Ti₃SiC₂ composite using electric field-assisted sintering technique. International Journal of Applied Ceramic Technology, 2021, 18(5): 1670. DOI URL
[43]	HUGHES L A, VAN BENTHEM K. Spark plasma sintering apparatus used for the formation of strontium titanate bicrystals. Journal of Visualized Experiments, 2017, 120: 1.
[44]	NISAR A, DOLMETSCH T, PAUL T, et al. Electric field assisted solid-state interfacial joining of TaC-HfC ceramics without filler. Journal of the American Ceramic Society, 2021, 104(6): 2483. DOI URL
[45]	LIU L, YE F, ZHOU Y, et al. Fast bonding α-SiAlON ceramics by spark plasma sintering. Journal of the European Ceramic Society, 2010, 30(12): 2683. DOI URL
[46]	TATARKO P, CHLUP Z, MAHAJAN A, et al. High temperature properties of the monolithic CVD beta-SiC materials joined with a pre-sintered MAX phase Ti₃SiC₂ interlayer via solid-state diffusion bonding. Journal of the European Ceramic Society, 2017, 37(4): 1205. DOI URL
[47]	YU Y, DONG H, MA B, et al. Effect of different filler materials on the microstructure and mechanical properties of SiC-SiC joints joined by spark plasma sintering. Journal of Alloys and Compounds, 2017, 708: 373. DOI URL
[48]	DONG H, YU Y, JIN X, et al. Microstructure and mechanical properties of SiC-SiC joints joined by spark plasma sintering. Ceramics International, 2016, 42(13): 14463. DOI URL
[49]	ZHAO X, DUAN L, WANG Y. Fast interdiffusion and Kirkendall effects of SiC-coated C/SiC composites joined by a Ti-Nb-Ti interlayer via spark plasma sintering. Journal of the European Ceramic Society, 2019, 39(5): 1757. DOI URL
[50]	ZHOU X, LIU J, ZOU S, et al. Almost seamless joining of SiC using an in-situ reaction transition phase of Y₃Si₂C₂. Journal of the European Ceramic Society, 2020, 40(2): 259. DOI URL
[51]	YANG H, ZHOU X, SHI W, et al. Thickness-dependent phase evolution and bonding strength of SiC ceramics joints with active Ti interlayer. Journal of the European Ceramic Society, 2017, 37(4): 1233. DOI URL
[52]	AKDOGAN E K, SAVKLIYILDIZ I, BICER H, et al. Anomalous lattice expansion in yttria stabilized zirconia under simultaneous applied electric and thermal fields: a time-resolved in situ energy dispersive X-ray diffractometry study with an ultrahigh energy synchrotron probe. Journal of Applied Physics, 2013, 113(23): 3503.
[53]	GRIMLEY C A, PRETTE A L G, DICKEY E C. Effect of boundary conditions on reduction during early stage flash sintering of YSZ. Acta Materialia, 2019, 174: 271. DOI URL
[54]	TODD R I, ZAPATA-SOLVAS E, BONILLA R S, et al. Electrical characteristics of flash sintering: thermal runaway of Joule heating. Journal of the European Ceramic Society, 2015, 35(6): 1865. DOI URL
[55]	ZHANG Y Y, NIE J Y, LUO J. Flash sintering activated by bulk phase and grain boundary complexion transformations. Acta Materialia, 2019, 181: 544. DOI URL
[56]	NAIK K S, SGLAVO V M, RAJ R. Flash sintering as a nucleation phenomenon and a model thereof. Journal of the European Ceramic Society, 2014, 34(15): 4063. DOI URL
[57]	RAJ R, COLOGNA M, FRANCIS J S C. Influence of externally imposed and internally generated electrical fields on grain growth, diffusional creep, sintering and related phenomena in ceramics. Journal of the American Ceramic Society, 2011, 94(7): 1941. DOI URL
[58]	CHAIM R. Liquid film capillary mechanism for densification of ceramic powders during flash sintering. Materials, 2016, 9(4): 280. DOI URL
[59]	CHAIM R, AMOUYAL Y. Liquid-film assisted mechanism of reactive flash sintering in oxide systems. Materials, 2019, 12(9): 1494. DOI URL
[60]	DONG Y H, CHEN I W. Predicting the onset of flash sintering. Journal of the American Ceramic Society, 2015, 98(8): 2333. DOI URL
[61]	YU M, GRASSO S, MCKINNON R, et al. Review of flash sintering: materials, mechanisms and modelling. Advances in Applied Ceramics, 2017, 116(1): 24. DOI URL
[62]	JI W, PARKER B, FALCO S, et al. Ultra-fast firing: effect of heating rate on sintering of 3YSZ, with and without an electric field. Journal of the European Ceramic Society, 2017, 37(6): 2547. DOI URL
[63]	ZHANG Y Y, JUNG J I, LUO J. Thermal runaway, flash sintering and asymmetrical microstructural development of ZnO and ZnO-Bi₂O₃ under direct currents. Acta Materialia, 2015, 94: 87. DOI URL
[64]	MISHRA T P, AVILA V, NETO R R I, et al. On the role of debye temperature in the onset of flash in three oxides. Scripta Materialia, 2019, 170: 81. DOI
[65]	TATARKO P, GRASSO S, SAUNDERS T G, et al. Flash joining of CVD-SiC coated C_f/SiC composites with a Ti interlayer. Journal of the European Ceramic Society, 2017, 37(13): 3841. DOI URL
[66]	XIA J B, REN K, WANG Y G. One-second flash joining of zirconia ceramic by an electric field at low temperatures. Scripta Materialia, 2019, 165: 34. DOI URL
[67]	FRANCIS J S C, RAJ R. Flash-sinter-forging of nanograin zirconia: field assisted sintering and super-plasticity. Journal of the American Ceramic Society, 2012, 95(1): 138. DOI URL
[68]	FRANCIS J S C, RAJ R. Influence of the field and the current limit on flash sintering at isothermal furnace temperatures. Journal of the American Ceramic Society, 2013, 96(9): 2754. DOI URL
[69]	CAO Y, XU G C, SHEN P. Flash joining of 3YSZ and 430 SS using Ag-CuO filler. Ceramics International, 2022, 48(3): 4005. DOI URL
[70]	XIA J B, REN K, LIU W, et al. Ultrafast joining of zirconia ceramics using electric field at low temperatures. Journal of the European Ceramic Society, 2019, 39(10): 3173. DOI URL
[71]	XIA J, REN K, WANG Y. Flash joining of alumina ceramics under a small current density. Journal of the European Ceramic Society, 2021, 41(4): 2782. DOI URL
[72]	SHI D. Research on the process and mechanism of BSCF ceramics’ flash sintering and flash joining. Harbin: Master Thesis of Harbin Institute of Technology, 2020.
[73]	XIA J, REN K, WANG Y. Rapid joining of heterogeneous ceramics with a composite interlayer under the action of an electric field. Journal of the European Ceramic Society, 2021, 41(14): 7164. DOI URL
[74]	XIA J B, REN K, WANG Y G. Reversible joining of zirconia to titanium alloy. Ceramics International, 2019, 45(2): 2509. DOI
[75]	XIA J B, REN K, WANG Y G, et al. Reversible flash-bonding of zirconia and nickel alloys. Scripta Materialia, 2018, 153: 31. DOI URL
[76]	CAO Y, XU G C, LI L, et al. Flash sintering of 3YSZ and in-situ joining with 304 stainless steel using copper as an interlayer. Scripta Materialia, 2021, 194: 5.
[77]	LI L, LIANG Y Z, CHEN S M, et al. Ultrafast and robust joining of 3YSZ and GH3128 superalloy using Cu interlayer under an electric field. Journal of Alloys and Compounds, 2022, 890: 161893. DOI URL

Joining method	Electric field type	Electric field	Joining current	Joining temperature	Joining time
FDB	DC	Small	Small	Low	Long
SPS	DC pulse	Small	Large	High	Short
FJ	DC/DC pulse	Large	Small	Low	Fast

Joining method	Electric field type	Electric field	Joining current	Joining temperature	Joining time
FDB	DC	Small	Small	Low	Long
SPS	DC pulse	Small	Large	High	Short
FJ	DC/DC pulse	Large	Small	Low	Fast

Joining system	Joining condition	Shear strength/MPa	Main phases at interface	Ref.
Al/β-Al₂O₃	500-600 ℃, 500 V, 1-2 h	—	No interlayer	[27]
Cu/ZrO₂	800 ℃ 50 V, 1 A, 20 min	—	Cu₂O, Cu-Zr	[32]
Ni/ZrO₂	1100 ℃, 10 mA, 30 min	160±15	Ni-Zr	[33]
Polycrystal ferrites/single crystalline ferrites	1200 ℃, 1 A, 24 h	—	No interlayer	[25]

Joining system	Joining condition	Shear strength/MPa	Main phases at interface	Ref.
Al/β-Al₂O₃	500-600 ℃, 500 V, 1-2 h	—	No interlayer	[27]
Cu/ZrO₂	800 ℃ 50 V, 1 A, 20 min	—	Cu₂O, Cu-Zr	[32]
Ni/ZrO₂	1100 ℃, 10 mA, 30 min	160±15	Ni-Zr	[33]
Polycrystal ferrites/single crystalline ferrites	1200 ℃, 1 A, 24 h	—	No interlayer	[25]

Joining system	Joining conditions	Joint strength characterization	Maximum average joint strength/MPa	Ref.
SiC/SiC	1900 ℃, 5 min, 3.5 MPa	Bending strength	260.24±12.00	[20]
LR-SiC/LR-SiC	1750 ℃, ~500 ℃/min, 800 A, 10 min, 50 MPa	—	—	[39]
HR-SiC/HR-SiC	2100 ℃, 100 ℃/min, 2400 A, 10 min, 50 MPa	—	—	[39]
CVD-SiC/CVD-SiC	1900 ℃, 50 ℃/min, 5 min, 60 MPa	Bending strength	436±1	[22]
Coated C/SiC/C/SiC	1700 ℃, 150-200 ℃/min, 3 min, 60 MPa	Shear strength	24.6	[40]
Ti₃SiC₂/Ti₃AlC₂	1200 ℃, 150 ℃/min, ~1.18 kA, <6 min, 15 MPa	Shear strength	~50	[41]
Ti₃SiC₂/Ti₃SiC₂	1300 ℃, 150 ℃/min, ~1.30 kA, <6 min, 15 MPa	Shear strength	~50	[41]
Ti₃AlC₂/Ti₃AlC₂	1300 ℃, 150 ℃/min, ~1.32 kA, <6 min, 15 MPa	Shear strength	~60	[41]
SiC_w/Ti₃SiC₂/SiC_w/Ti₃SiC₂	1090 ℃, 100 ℃/min, 586 A·cm^-2, 30 s, 30 MPa	Shear strength	51.8±2.9	[42]
STO bicrystal/STO bicrystal	1200 ℃, 70-80 ℃/min, ~550 A, 15 min, 140 MPa	—	—	[43]
TaC/HfC	1850 ℃, 10 min, 60 MPa	—	—	[44]
α-SiAlON/α-SiAlON	1650 ℃, 10 min, 20 MPa	Bending strength	~610	[45]