Co-Sintering behaviour of zirconia-ferritic steel composites

Today, there is a high demand and increasing trend for multifunctional composite materials and components due to the combination of a wide range of favorable properties. However, undesired deformation leading to delamination, curvature, cracks, or even complete fracture frequently occurs during the co‐sintering process of metal–ceramic laminates (MCLs). To solve these issues, experimental work highly relies on the time‐consuming trial‐and‐error principle. This work aims to develop a thermo‐mechanical‐metallurgical model capable of predicting the densification, deformation, and delamination of MCLs during the co‐sintering process. It is found that the developed model successfully considers the inhomogeneous relative density distribution and phase transformation of the steel tape. In addition, a thin interlayer formed by a mixed slurry in the MCLs is modeled as cohesive elements to simulate the delamination process. The developed model is systematically validated by the experimental measurements and observations in terms of densification, deformation, and delamination during the co‐sintering process of the investigated laminate variants.

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Investigation on the Curvature and Stress Distribution of Laminates Based on an Analytic Solution and FE Simulation

Liu

Günther

Deng

et al. 2022

Materials

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The potential combinations of favorable properties give metal–ceramic laminates (MCLs) a high degree of application flexibility. However, the different thermal expansion coefficients (CTEs) and shrinkage rates of the metals and ceramics during the co-sintering process often lead to large internal stresses that cause undesired deformation or even production failures. In practice, the identification of manufacturable MCLs relies on the “trial and error” principle, which usually requires a long development period. Therefore, there is a great demand for analytic and numerical methods that allow the prediction of the deformation and manufacturability of MCLs during the co-sintering process. The main objective of this study is to investigate the curvature and stress distribution in the MCLs (steel 17-4PH/ ceramic 3Y-TZP) based on the analytic solution and finite element (FE) simulation. To achieve this, the Young’s moduli (E) and shear moduli (G) at high temperatures and the CTEs of both materials were measured. In addition, the curvatures and stress distributions of the two-layer and three-layer laminates were obtained based on the analytic method and FE simulation, which were in very good agreement. Furthermore, the influence of the CTE, Young’s modulus, height ratio, and interface on the curvature were studied. The results showed that the CTE and height ratio have a higher influence on the curvature in comparison to the Young’s modulus. The interface prevents the curvature significantly by assuming it to be a cohesive surface in the FE simulation. This provides hints to avoid delamination during the manufacturing process.

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Co-Sintering behaviour of zirconia-ferritic steel composites

Cited by 3 publications

References 15 publications

Controlling the sintering response in the development of multilayered components produced via powder injection molding route—a review

Controlling the sintering response in the development of multilayered components produced via powder injection molding route—a review

Densification, deformation, and delamination during co‐sintering process of metal–ceramic laminates

Investigation on the Curvature and Stress Distribution of Laminates Based on an Analytic Solution and FE Simulation

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