Analytical and experimental evaluation of joining ceramic oxides to ceramic oxides and ceramic oxides to metal for advanced heat engine applications

Abstract

The problem of designing reliable, high strength zirconia-to-zirconia and zirconia-tonodular cast iron joints is addressed by developing a general joint design and assessment methodology. A joint's load carrying capability is predicted in terms of its material strength and fracture toughness characteristics. The effects ofjoint constituent properties and joining process variables are included. The methodology is verified in a two step process by applying it first to notched bend bars and then to a notched disk specimen loaded in compression. Key technical accomplishments in the program include the development of a joint design and assessment methodology which predicts failure based on a combination of strength _tndtoughness, tile development of a new method of hot forging magnesia partially stabilized zirconia to itse.'f, and the development of a bimaterial disk-shaped specimen notched along the diametral bond line and compressively loaded to generate both shear and tensile loadings on the bond line. Mechanical and thermal characterization ofjoints, adherents, and interlayer materials were performed to provide data for input to the design methodology. Results from over 150 room temperature tests and 30 high temperature tests are reported. Extensive comparisons of experimental results are made with model predictions of failure load. The joint design and assessment model, as applied to the materials and test specimens of this program, has been programmed for a PC and is available to interested researchers.