Different joining techniques to create complex alumina ceramic shapes at relatively low temperatures
STOSZ M. 1, NARAYANASAMY S. 1, BLUGAN G. 1
1 Empa - Swiss Federal Laboratories for Material Science and Technology, Dübendorf, Switzerland
Alumina is known for its good thermal conductivity, high temperature stability, high strength, and low material costs. Therefore, it has many industrial applications in advanced and traditional fields. Alumina ceramics are usually obtained by sintering alumina powders previously formed into a desirable shape. However, it limits their use, because manufacturing objects with large dimensions or complicated shapes becomes difficult. Joining simple components together to make more complicated shapes is one of the relatively low-cost solutions that helps to overcome the current difficulty. Usually, indirect bonding is applied through the additional interlayer between ceramics to obtain durable joints at lower than sintering of ceramic temperature. In this research, alumina ceramics were chemically bonded at relatively low temperatures with the use of 3 different interlayers. As the first interlayer, mixed powders of Bi2O3 and ZnO with different weight ratios were applied to perform transient liquid phase bonding (TLP). Bonding was achieved at 750°C for several of the prepared interlayer compositions, which makes the applied approach attractive due to the low joining temperature and potentially low fabrication costs. SEM and EDX were used to study the microstructure and chemical analysis of the obtained joints. It also allowed the investigation of the diffusion mechanism occurring in the systems, which resulted in the hypothesis that Zn2+/ZnO diffuses through the ceramics. XRD and Raman spectra were acquired to examine the reaction products that formed during the thermal treatment. The results showed that both ZnO and Bi2O3 react with each other as well as with alumina forming spinel and other products. Additionally, alumina ceramics were joined through the diffusion bonding mechanism by spark plasma sintering technology using zirconium and titanium metals as interlayers. Bonding with Zr was achieved at 800 and 900°C with an applied force of 4.2 kN and then at 900°C with the force of 3 kN. It was found that Ti bonded to alumina at 700, 800, and 900°C with an applied force of 3 kN. The influence of temperature and pressure on the bonding properties was measured for both interlayers. SEM was used to examine the quality of the bonded ceramics and EDX was used to gain insights into the bonding mechanism. The best joints were obtained at 900°C for Zr and 800°C for Ti. Oxygen diffusion via the formation of oxygen defects/vacancies and the formation of the reaction products such as ZrO2 (and some Ti-Al or TiO2 reaction products) could underpin the possible bonding mechanisms.