Spark Plasma Joining of ZrB₂–SiC Composites Using Zirconium–Boron Reactive Filler Layers

Abstract

Spark plasma joining is used to join ZrB2–SiC composites with seamless microstructures at the joint that results in retention of high‐temperature mechanical and oxidation properties after joining. Our approach uses a spark plasma sintering furnace and Zr–B powder filler layers to join the parts together. The joining processing parameters used to optimize the joint microstructure were filler composition, target temperature, hold time, and volume of filler. A filler of 1 mm3 and spark plasma joining conditions at 1800°C for 300 s resulted in the formation of a joint region that was indistinguishable from the bulk substrates. Room and high‐temperature (1350°C) shear strengths of joined substrates measured equal to baseline substrates and oxidation behavior for joined and baseline substrates were equivalent after static air oxidation at 1700°C. X‐Ray diffraction measurements show the joint is composed of ZrB2 and ZrC. We found the joining mechanism to be solid‐state bonding of ZrB2 that formed from the Zr–B filler and reaction bonding by the formation of ZrC. Spark plasma joining rapidly joins ZrB2–SiC and probably other conductive ultra high‐temperature ceramic composites, and has the potential to impact the rapid assembly and joining of complex thermal protection material systems.

Fast joining SiC ceramics with Ti3SiC2 tape film by electric field-assisted sintering technology

“…A C C E P T E D ACCEPTED MANUSCRIPT 4 sometimes referred to the spark plasma sintering, SPS) has been employed successfully to join Zr-alloy cladding tubes [16], ZrB 2 -SiC composites [17], MAX phase [18], and SiC and C/SiC composites within a 3 -10 minutes holding time [19]. S. Grasso et al [20] successfully joined β-SiC with or without Ti foil by SPS.…”

Control of Interfacial Reactivity Between ZrB2 and Ni-Based Brazing Alloys

“…A broad survey of the results for diborides of the metals belonging to the IV Group (Ti, Zr, and Hf) can be found in Passerone et al (Ref 9,10) and in Muolo et al (Ref 11). On top of the wetting studies, many articles appeared in the last ten years describing joining processes or metal-ceramic composite formation especially for TiB 2 and ZrB 2 (Ref [16][17][18][19][20][21][22][23], while just a few studies involve HfB 2 (Ref 11,24).…”

Investigation of Ni-B Alloys for Joining of TiB2 Ultra-High-Temperature Ceramic

“…This suggests essential dependence of performance of structural ceramic components on the quality and reliability of joints (Ref [6][7][8][9][10][11]. Therefore, development of desired joints without defects but with satisfactory strength is critical for successful integration into engineering applications.…”