Home      Exposition      To Register      ASM Homepage
Back to "Session 3: Ceramic and Glass Joining 1" Search
    Back to Main Search

Monday, April 24, 2006 - 2:50 PM
BSC3.5

Component Development using a Coupled Analysis and Experimental Approach: Ceramic-Ceramic and Ceramic-Metal Joining

R. Tandon, J. T. McLaughlin, M. A. Neidigk, J. E. Massad, T. E. Buchheit, Sandia National Lab, Albuquerque, NM

The brittle nature of ceramic materials makes it imperative that ceramic based components have little or no residual tensile stress when joined to metals, and low tensile stress during operation. During development of an interrupted transformer switch containing a magnetic ferrite (ZnxMn1-xO. Fe2O3) ceramic, the low toughness of the ferrite led to failures during soldering the ceramic to copper and during subsequent  mechanical testing. Strength of the ferrite-copper bond was extremely process dependent, and it was difficult to reproducibly obtain high peel strengths. To overcome these issues, a hierarchy of joining techniques were utilized during prototyping. To reduce tensile stress during operation, two half-moon shaped disks of ferrite were joined to a thermally matched glass-ceramic using glass bonding. The residual stress near the interface was evaluated both experimentally and using FEA.  The processing parameters and composition of glass bonded regions were modified to obtain essentially zero stress in the ferrite. Strength testing of bonded sections indicated that failures occurred predominantly in the ferrite, away from the interface, indicating a strong bond. An alternative metal-ceramic joining process, capture of the bonded assembly using a Ni/Ti/Nb shape memory alloy (SMA), was successfully employed. The constitutive behavior of the SMA under stress was obtained and a corresponding material model was used with FEA to predict the stresses in the ferrite. The stresses were experimentally validated. The SMA captured assembly was soldered into a stainless steel body using peel testing to identify the appropriate electroplating process. A robust prototype capable of withstanding mechanical and shock loadings was obtained. This paper summarizes the various schemes developed for the design and manufacture of this component.

 

Sandia is a multi-program laboratory operated by Sandia Corporation, a Lockheed Martin Company, for the United States Department of Energy’s National Nuclear Security Administration under Contract-DE-AC04-94AL85000.

Summary: The brittle nature of ceramic materials makes it imperative that ceramic based components have little or no residual tensile stress when joined to metals, and low tensile stress during operation. Here, we describe a hierarchy of joining techniques that were used to prototype and manufacture a ceramic (ferrite) based component. The ferrite was joined to a non-magnetic glass-ceramic using glass bonding to reduce the stresses in the ferrite during operation. Soldering this assembly to copper was found to lead to failures in the ferrite. So an alternative process, mechanically capturing the disk in a shape memory alloy (SMA), was utilized. The SMA assembly was then soldered to a stainless steel body to form the functional component. At each step, finite element analysis and experimental validation techniques were used to ensure that the stresses in the ceramic material remained close to zero. The results of the work were a robust prototype, and schemes that are currently being used to manufacture the component.