Novel design of metal-ceramic joints using additive manufacturing
MALIK R. 1, OOSTERBEEK R. 2, FANTETTI A. 1
1 Imperial College London, London, United Kingdom; 2 University of Oxford, Oxford, United Kingdom
This work proposes a novel approach to fabricating metal-ceramic joints using state-of-art additive manufacturing techniques. The titanium and alumina substrates were joined together using a 1.5 mm thick interface of interpenetrating titanium and alumina lattices fabricated by laser powder bed fusion and slurry infiltration. Mechanical interlocking and compression fitting of the two lattices in the interface resulted in a shear strength of > 60 MPa. The effect of interface design on the joint strength was investigated and related to the residual stresses determined using finite element modeling. The fracture behavior was characterized using an in-situ bending test. The interface microstructure was characterized using X-ray tomography and SEM-EDS. This new approach to multi-material bonding is expected to spark significant new research in the field of additive manufacturing-assisted joining technology, of use in many other metal-ceramic and multi-material systems across a range of applications from aerospace to healthcare.