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Tuesday, April 25, 2006 - 8:40 AM
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Microwave Brazing of Ceramics to Metals

R. P. Radtke, Technology International, Inc., Kingwood, TX

Successful microwave brazing of ceramics to metals was first observed using an existing NASA Jet Propulsion Laboratory (JPL) variable frequency TWT powered single-mode microwave reactor.  It was discovered that selected ceramic materials and braze filler metals absorb microwave energy more efficiently than the base metal.  In fact, the ceramic was observed to be at white heat while the metal was black.  The microwave susceptibility of these and other ceramic-to-metal material pairs will be reported. The microwave brazing process results in preferential heating of the lower expanding ceramic, thus providing the ability to match the thermal contraction of the dissimilar material pair on cool-down.  Peak electrical and magnetic locations within the reactor were determined empirically and verified with models to aid in the accurate control of ceramic and braze filler metal temperatures throughout the brazing cycle. For production brazing, a custom built 2.45 GHz magnetron powered reactors were designed.  Process development resulted in improved process control and a viable commercial microwave brazing process.  Successful applications of microwave brazing have resulted in high attachment strength with dissimilar material pairs.  For example, thermally stable polycrystalline diamond and tungsten carbide, and silicon carbide and a titanium alloy.  Tungsten carbide has a thermal expansion coefficient 2 times greater than a thermally stable polycrystalline diamond.  Preferential microwave heating of the diamond layer and braze filler metal creates the ability to control residual brazing stresses in the diamond layer.  Preferential heating of the braze filler metal results in a reduction in porosity and other defects.  Ceramic-to metal-pairs with attachment shear strength of over 414 MPa (60,000 psi) has been achieved.  Microwave brazing has other applications including cutting tools, drill bit cutters, abrasives, ceramic substrates for electronic devices, turbocharger rotors, turbine blades, automotive engine components, nuclear fuel rods, heating elements, heat exchangers, and fuel cells. 

Summary: Microwave brazing of ceramics to metals is both quick and efficient, and industry is becoming increasingly aware of its potential. Microwaves have long been considered as an energy source for diffusion bonding ceramics such as alumina, zirconia, mullite, silicon nitride and silicon carbide. However, microwave brazing methods for joining ceramics to metals is relatively new. Technology International, Inc., with the cooperation of NASA JPL and the Colorado School of Mines, has developed a unique brazing method. The inventors were awarded the NASA Space Act Award for Innovation.