Journal of Inorganic Materials ›› 2023, Vol. 38 ›› Issue (2): 113-124.DOI: 10.15541/jim20220400
• REVIEW • Next Articles
LIU Yan1(
), ZHANG Keying1,2, LI Tianyu1,2, ZHOU Bo1,2, LIU Xuejian1, HUANG Zhengren1
Received:2022-07-09
Revised:2022-09-20
Published:2023-02-20
Online:2022-09-22
About author:LIU Yan (1975-), male, PhD, professor. E-mail: stony2000@mail.sic.ac.cn
Supported by:CLC Number:
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.
Fig. 1 Joining technology of ceramics and their applications[13]
| 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 |
Table 1 Comparison of three electric-field assisted joining technologies
| 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 |
Fig. 2 Equipment and mechanism of FDB [25-26] (a) FDB experimental equipment; (b) Joining mechanism of ceramic and metal
| Joining system | Joining condition | Shear strength/MPa | Main phases at interface | Ref. |
|---|---|---|---|---|
| Al/β-Al2O3 | 500-600 ℃, 500 V, 1-2 h | — | No interlayer | [ |
| Cu/ZrO2 | 800 ℃ 50 V, 1 A, 20 min | — | Cu2O, Cu-Zr | [ |
| Ni/ZrO2 | 1100 ℃, 10 mA, 30 min | 160±15 | Ni-Zr | [ |
| Polycrystal ferrites/single crystalline ferrites | 1200 ℃, 1 A, 24 h | — | No interlayer | [ |
Table 2 FDB of ionic conductive ceramics
| Joining system | Joining condition | Shear strength/MPa | Main phases at interface | Ref. |
|---|---|---|---|---|
| Al/β-Al2O3 | 500-600 ℃, 500 V, 1-2 h | — | No interlayer | [ |
| Cu/ZrO2 | 800 ℃ 50 V, 1 A, 20 min | — | Cu2O, Cu-Zr | [ |
| Ni/ZrO2 | 1100 ℃, 10 mA, 30 min | 160±15 | Ni-Zr | [ |
| Polycrystal ferrites/single crystalline ferrites | 1200 ℃, 1 A, 24 h | — | No interlayer | [ |
Fig. 3 Interfacial SEM micrographs of manganese-zinc ferrite poly- and single-crystals under different bonding conditions[25] (a) 1000 ℃, 1 h, not etched; (b) 1200 ℃, 1 h, not etched; (c) 1200 ℃, 12 h, not etched; (d) 1000 ℃, 1 h, etched; (e) 1200 ℃, 1 h, etched; (f) 1200 ℃, 12 h, etched. Current for all cases is 1 A
Fig. 4 Cross-sectional microstructures at the Ni/ZrO2 interfaces after joining under different current intensities and polarities[33] (a) +30 mA; (b) +60 mA; (c) −60 mA. The elemental mapping graphs correspond to the magnified frame area in image (c)
Fig. 5 TEM micrographs of the Al2O3/Ti joint bonded at 900 ℃ for 1 h under 700 V DC field [34] (a-c) Morphologies of the reaction layer (a), magnified zone B (b) and magnified zone C (c); (d) Electron diffraction (SAED) patterns of the phases
Fig. 6 Working schematic of an SPS apparatus[38]
| 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 | [ |
| LR-SiC/LR-SiC | 1750 ℃, ~500 ℃/min, 800 A, 10 min, 50 MPa | — | — | [ |
| HR-SiC/HR-SiC | 2100 ℃, 100 ℃/min, 2400 A, 10 min, 50 MPa | — | — | [ |
| CVD-SiC/CVD-SiC | 1900 ℃, 50 ℃/min, 5 min, 60 MPa | Bending strength | 436±1 | [ |
| Coated C/SiC/C/SiC | 1700 ℃, 150-200 ℃/min, 3 min, 60 MPa | Shear strength | 24.6 | [ |
| Ti3SiC2/Ti3AlC2 | 1200 ℃, 150 ℃/min, ~1.18 kA, <6 min, 15 MPa | Shear strength | ~50 | [ |
| Ti3SiC2/Ti3SiC2 | 1300 ℃, 150 ℃/min, ~1.30 kA, <6 min, 15 MPa | Shear strength | ~50 | [ |
| Ti3AlC2/Ti3AlC2 | 1300 ℃, 150 ℃/min, ~1.32 kA, <6 min, 15 MPa | Shear strength | ~60 | [ |
| SiCw/Ti3SiC2/SiCw/Ti3SiC2 | 1090 ℃, 100 ℃/min, 586 A·cm-2, 30 s, 30 MPa | Shear strength | 51.8±2.9 | [ |
| STO bicrystal/STO bicrystal | 1200 ℃, 70-80 ℃/min, ~550 A, 15 min, 140 MPa | — | — | [ |
| TaC/HfC | 1850 ℃, 10 min, 60 MPa | — | — | [ |
| α-SiAlON/α-SiAlON | 1650 ℃, 10 min, 20 MPa | Bending strength | ~610 | [ |
Table 3 SPS joining of ceramic material without interlayer
| 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 | [ |
| LR-SiC/LR-SiC | 1750 ℃, ~500 ℃/min, 800 A, 10 min, 50 MPa | — | — | [ |
| HR-SiC/HR-SiC | 2100 ℃, 100 ℃/min, 2400 A, 10 min, 50 MPa | — | — | [ |
| CVD-SiC/CVD-SiC | 1900 ℃, 50 ℃/min, 5 min, 60 MPa | Bending strength | 436±1 | [ |
| Coated C/SiC/C/SiC | 1700 ℃, 150-200 ℃/min, 3 min, 60 MPa | Shear strength | 24.6 | [ |
| Ti3SiC2/Ti3AlC2 | 1200 ℃, 150 ℃/min, ~1.18 kA, <6 min, 15 MPa | Shear strength | ~50 | [ |
| Ti3SiC2/Ti3SiC2 | 1300 ℃, 150 ℃/min, ~1.30 kA, <6 min, 15 MPa | Shear strength | ~50 | [ |
| Ti3AlC2/Ti3AlC2 | 1300 ℃, 150 ℃/min, ~1.32 kA, <6 min, 15 MPa | Shear strength | ~60 | [ |
| SiCw/Ti3SiC2/SiCw/Ti3SiC2 | 1090 ℃, 100 ℃/min, 586 A·cm-2, 30 s, 30 MPa | Shear strength | 51.8±2.9 | [ |
| STO bicrystal/STO bicrystal | 1200 ℃, 70-80 ℃/min, ~550 A, 15 min, 140 MPa | — | — | [ |
| TaC/HfC | 1850 ℃, 10 min, 60 MPa | — | — | [ |
| α-SiAlON/α-SiAlON | 1650 ℃, 10 min, 20 MPa | Bending strength | ~610 | [ |
Fig. 7 Fractured micrographs of the TaC-HfC joint [44] (a) Low magnification fractured image; (b-d) High-resolution fractured images of the interface eliciting the presence of slip lines on (b) TaC side, (c) TaC-HfC interface, and (d) HfC side
| Joining system | Interlayer | Joining conditions | Joint strength characterization | Maximum joint strength/MPa | Main phases at interface | Ref. |
|---|---|---|---|---|---|---|
| SiC/SiC | 4.5YSZ | 1700 ℃, 150 ℃/min, 40 MPa | Bending strength | 26.7 | ZrO2 | [ |
| SiC/SiC | 4.5YSZ+ 20% Al2O3 (in mass) | 1800 ℃, 100-200 ℃/min, 40 MPa | Bending strength | 107.3 | ZrO2, mZrO2 | [ |
| SiC/SiC | TSC | 1900 ℃, 5 min, 3.5 MPa | Bending strength | 230.6±19 | TiC, Ti, Al | [ |
| SiC/SiC | TAC | 1900 ℃, 5 min, 3.5 MPa | Bending strength | 230.5±13 | TiC, Al, Ti | [ |
| SiC/SiC | TSC | 1300 ℃, 100-200 ℃/min, 15 min, 50 MPa | Bending strength | 80.4 | TiCx, TixSiy | [ |
| SiC/SiC | TSC | 1400 ℃, 100-200 ℃/min, 30 MPa | Bending strength | 66 | TiSi2, TiC | [ |
| SiC/SiC | TSC | 1600 ℃, 30 min, 20-40 MPa | Bending strength | 110.4 | TSC, TiC | [ |
| CVD-SiC/ CVD-SiC | TSC | 1300 ℃, 100 ℃/min, 5 min, 50 MPa | Bending strength | 220.3±3.2 | TSC | [ |
| Coated SiCf/SiC/ coated SiCf/SiC | TSC | 1300 ℃, 100 ℃/min, 5 min, 50 MPa | Shear strength | 18.3±5.8 | TSC | [ |
| Coated Cf/SiC/ coated Cf/SiC | TSC | 1300 ℃, 100 ℃/min, 5 min, 50 MPa | Shear strength | 31.1±4.0 | TSC | [ |
| Uncoated T300 1K Cf/SiC/uncoated T300 1K Cf/SiC | TSC | 1300 ℃, 100 ℃/min, 5 min, 50 MPa | Shear strength | 19.1±2.0 | TSC, SiC | [ |
| Uncoated M40J 3K Cf/SiC/uncoated M40J 3K Cf/SiC | TSC | 1300 ℃, 100 ℃/min, 5 min, 50 MPa | Shear strength | 5.5±1.8 | TSC, SiC | [ |
| Coated C/SiC/ coated C/SiC | CA | 1480 ℃, 50 ℃/min, 10 min, 0 MPa | Shear strength | ~14.1 | CA | [ |
| Coated C/SiC/ coated C/SiC | SiC+B4C | 1900 ℃, 150-200 ℃/min, 3 min, 60 MPa | Shear strength | 18.2 | — | [ |
| Cf/SiC/Cf/SiC | TSC | 1600 ℃, 30 min, 20-40 MPa | Bending strength | 62.6 | TSC, TiC | [ |
Table 4 SPS joining of ceramic material with inorganic material interlayer
| Joining system | Interlayer | Joining conditions | Joint strength characterization | Maximum joint strength/MPa | Main phases at interface | Ref. |
|---|---|---|---|---|---|---|
| SiC/SiC | 4.5YSZ | 1700 ℃, 150 ℃/min, 40 MPa | Bending strength | 26.7 | ZrO2 | [ |
| SiC/SiC | 4.5YSZ+ 20% Al2O3 (in mass) | 1800 ℃, 100-200 ℃/min, 40 MPa | Bending strength | 107.3 | ZrO2, mZrO2 | [ |
| SiC/SiC | TSC | 1900 ℃, 5 min, 3.5 MPa | Bending strength | 230.6±19 | TiC, Ti, Al | [ |
| SiC/SiC | TAC | 1900 ℃, 5 min, 3.5 MPa | Bending strength | 230.5±13 | TiC, Al, Ti | [ |
| SiC/SiC | TSC | 1300 ℃, 100-200 ℃/min, 15 min, 50 MPa | Bending strength | 80.4 | TiCx, TixSiy | [ |
| SiC/SiC | TSC | 1400 ℃, 100-200 ℃/min, 30 MPa | Bending strength | 66 | TiSi2, TiC | [ |
| SiC/SiC | TSC | 1600 ℃, 30 min, 20-40 MPa | Bending strength | 110.4 | TSC, TiC | [ |
| CVD-SiC/ CVD-SiC | TSC | 1300 ℃, 100 ℃/min, 5 min, 50 MPa | Bending strength | 220.3±3.2 | TSC | [ |
| Coated SiCf/SiC/ coated SiCf/SiC | TSC | 1300 ℃, 100 ℃/min, 5 min, 50 MPa | Shear strength | 18.3±5.8 | TSC | [ |
| Coated Cf/SiC/ coated Cf/SiC | TSC | 1300 ℃, 100 ℃/min, 5 min, 50 MPa | Shear strength | 31.1±4.0 | TSC | [ |
| Uncoated T300 1K Cf/SiC/uncoated T300 1K Cf/SiC | TSC | 1300 ℃, 100 ℃/min, 5 min, 50 MPa | Shear strength | 19.1±2.0 | TSC, SiC | [ |
| Uncoated M40J 3K Cf/SiC/uncoated M40J 3K Cf/SiC | TSC | 1300 ℃, 100 ℃/min, 5 min, 50 MPa | Shear strength | 5.5±1.8 | TSC, SiC | [ |
| Coated C/SiC/ coated C/SiC | CA | 1480 ℃, 50 ℃/min, 10 min, 0 MPa | Shear strength | ~14.1 | CA | [ |
| Coated C/SiC/ coated C/SiC | SiC+B4C | 1900 ℃, 150-200 ℃/min, 3 min, 60 MPa | Shear strength | 18.2 | — | [ |
| Cf/SiC/Cf/SiC | TSC | 1600 ℃, 30 min, 20-40 MPa | Bending strength | 62.6 | TSC, TiC | [ |
Fig. 8 Backscattered SEM images of the polished cross section of the CVD β-SiC joined with the pre-sintered Ti3SiC2 foil using SPS[46]
| Joining system | Interlayer | Joining conditions | Joint strength characterization | Maximum joint strength/MPa | Main phases at interface | Ref. |
|---|---|---|---|---|---|---|
| SiC/SiC | Y | 1900 ℃, 100 ℃/min, 10 min, 50 MPa | Bending strength | 134.8±2.1 | ZrO2 | [ |
| SiC/SiC | Ti | 1000 ℃, 100 ℃/min, 5 min, 30 MPa | Bending strength | 205.7±24 | ZrO2, mZrO2 | [ |
| SiC/SiC | 3Ti/1.2Si/ 2C/0.2Al | 1600 ℃, 100-200 ℃/min, 30 MPa | Bending strength | 133 | TiC, Ti, Al | [ |
| SiC coated C/SiC/ SiC coated C/SiC | Ti/Nb/Ti | 1200 ℃, 100 ℃/min, 5 min, 50 MPa | Shear strength | 61±6 | TiC, Al, Ti | [ |
| CVD-SiC/CVD-SiC | Ti | 1700 ℃, 50 ℃/min, 5 min, 60 MPa | Bending strength | 126±16 | TiCx, TixSiy | [ |
| Coated C/SiC/ coated C/SiC | Ti | 1700 ℃, 150-200 ℃/min, 3 min, 60 MPa | Shear strength | 17.3±7.8 | TiSi2, TiC | [ |
Table 5 SPS joining of ceramic material with metal interlayer
| Joining system | Interlayer | Joining conditions | Joint strength characterization | Maximum joint strength/MPa | Main phases at interface | Ref. |
|---|---|---|---|---|---|---|
| SiC/SiC | Y | 1900 ℃, 100 ℃/min, 10 min, 50 MPa | Bending strength | 134.8±2.1 | ZrO2 | [ |
| SiC/SiC | Ti | 1000 ℃, 100 ℃/min, 5 min, 30 MPa | Bending strength | 205.7±24 | ZrO2, mZrO2 | [ |
| SiC/SiC | 3Ti/1.2Si/ 2C/0.2Al | 1600 ℃, 100-200 ℃/min, 30 MPa | Bending strength | 133 | TiC, Ti, Al | [ |
| SiC coated C/SiC/ SiC coated C/SiC | Ti/Nb/Ti | 1200 ℃, 100 ℃/min, 5 min, 50 MPa | Shear strength | 61±6 | TiC, Al, Ti | [ |
| CVD-SiC/CVD-SiC | Ti | 1700 ℃, 50 ℃/min, 5 min, 60 MPa | Bending strength | 126±16 | TiCx, TixSiy | [ |
| Coated C/SiC/ coated C/SiC | Ti | 1700 ℃, 150-200 ℃/min, 3 min, 60 MPa | Shear strength | 17.3±7.8 | TiSi2, TiC | [ |
Fig. 9 Microstructures of CVD-SiC/Ti/Nb/Ti/CVD-SiC joint[49] (a) 1000 ℃; (b) 1200 ℃; (c) 1400 ℃; (d) 1600 ℃
Fig. 10 Schematic diagram and performance of flash joining[24] (a) Schematic of the joining apparatus; (b) Changes of the current, voltage and power dissipation with time
Fig. 11 Schematic diagrams of interfacial microstructure evolution of 3YSZ/Ag-CuO/430SS assembly[69] (a) Furnace heating stage; (b) Joule heating, electrochemical reduction of 3YSZ and formation of AgCu4Zr and Zr-rich IMCs
| Joining system | Joining conditions | Joint strength characterization | Maximum average joint strength/MPa | Ref. |
|---|---|---|---|---|
| 3YSZ/3YSZ | 900 ℃, 30 V/cm, 100 mA/mm2, 6 MPa, 1 s | Bending strength | 595 | [ |
| CVD-SiC/Ti/Cf/SiC | 1250 ℃, 2.2 kW, 370 A, 16 MPa, 7 s | Shear strength | 31.4 | [ |
| 3YSZ/3YSZ | 800 ℃, 50 V/cm, 100 mA/mm2, 6 MPa, 18 s | Bending strength | 606±18 | [ |
| MgO-doped Al2O3/MgO-doped Al2O3 | 1300 ℃, 1500 V/cm, 0.1 A, 4 MPa, 30 s | Shear strength | 146 | [ |
| BSCF/BSCF | 1000 ℃, 10 V/cm, 0.45 A/mm2, 10 s | — | — | [ |
| ZrO2/ZA/Al2O3 | 1200 ℃, 1800 V/cm, 0.3 A, 4 MPa, 30 s | Shear strength | 3YSZ/ZA: ~65 ZA/Al2O3: ~30 | [ |
Table 6 Flash joining between ceramics
| Joining system | Joining conditions | Joint strength characterization | Maximum average joint strength/MPa | Ref. |
|---|---|---|---|---|
| 3YSZ/3YSZ | 900 ℃, 30 V/cm, 100 mA/mm2, 6 MPa, 1 s | Bending strength | 595 | [ |
| CVD-SiC/Ti/Cf/SiC | 1250 ℃, 2.2 kW, 370 A, 16 MPa, 7 s | Shear strength | 31.4 | [ |
| 3YSZ/3YSZ | 800 ℃, 50 V/cm, 100 mA/mm2, 6 MPa, 18 s | Bending strength | 606±18 | [ |
| MgO-doped Al2O3/MgO-doped Al2O3 | 1300 ℃, 1500 V/cm, 0.1 A, 4 MPa, 30 s | Shear strength | 146 | [ |
| BSCF/BSCF | 1000 ℃, 10 V/cm, 0.45 A/mm2, 10 s | — | — | [ |
| ZrO2/ZA/Al2O3 | 1200 ℃, 1800 V/cm, 0.3 A, 4 MPa, 30 s | Shear strength | 3YSZ/ZA: ~65 ZA/Al2O3: ~30 | [ |
Fig. 12 SEM images of 3YSZ joint[24] (a) As-received 3YSZ ceramic; (b) Joint formed at 600 ℃; (c) Joint formed at 800 ℃
| Joining system | Joining conditions | Joint strength characterization | Maximum joint strength/MPa | Main phases at interface | Ref. |
|---|---|---|---|---|---|
| ZrO2/Ti-alloy | 700 ℃, 100 V/cm, 70 mA/mm2, 30 s,10 MPa | Shear strength | 67±9 | Ti, Zr | [ |
| ZrO2/Ni-alloy | 800 ℃, 100 V/cm, 100 mA/mm2, 1 s, 5 MPa | Shear strength | 133 | Ni, Zr | [ |
| 3YSZ/Ag-CuO/430SS | 950 ℃, 80 V/cm, 40 mA/mm2, 30 s, 0.7 MPa | Shear strength | 158±9 | AgCu4Zr | [ |
| 3YSZ/Cu/304SS | 1200 ℃, 50 V/cm, 100 mA/mm2, 30 s, 6 MPa | Shear strength | 21±4 | Cu-Zr | [ |
| 3YSZ/Cu/GH3128 | 1000 ℃, 30 mA/mm2, 30 s, 0.1 MPa | Shear strength | 250±15 | Cu-Zr | [ |
Table 7 Flash joining between ceramics and metals
| Joining system | Joining conditions | Joint strength characterization | Maximum joint strength/MPa | Main phases at interface | Ref. |
|---|---|---|---|---|---|
| ZrO2/Ti-alloy | 700 ℃, 100 V/cm, 70 mA/mm2, 30 s,10 MPa | Shear strength | 67±9 | Ti, Zr | [ |
| ZrO2/Ni-alloy | 800 ℃, 100 V/cm, 100 mA/mm2, 1 s, 5 MPa | Shear strength | 133 | Ni, Zr | [ |
| 3YSZ/Ag-CuO/430SS | 950 ℃, 80 V/cm, 40 mA/mm2, 30 s, 0.7 MPa | Shear strength | 158±9 | AgCu4Zr | [ |
| 3YSZ/Cu/304SS | 1200 ℃, 50 V/cm, 100 mA/mm2, 30 s, 6 MPa | Shear strength | 21±4 | Cu-Zr | [ |
| 3YSZ/Cu/GH3128 | 1000 ℃, 30 mA/mm2, 30 s, 0.1 MPa | Shear strength | 250±15 | Cu-Zr | [ |
Fig. 13 Shear strength of the 3YSZ/Ti-alloy joint under different conditions[74] (a) 700 ℃ and 30 s at different current densities; (b) 700 ℃ at current density of 70 mA/mm2 for different time; (c) Current density of 70 mA/mm2 for 30 s at different temperatures
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