Systems and methods for concurrent reaction-bonded joining and densification
A method can include providing two or more parts. The two or more parts can include a first part and a second part. The method can include disposing a source material between the first part and the second part. The method can include joining and densifying the first part and the second part by reacting a liquid with the source material.
1 . A method, comprising:
providing two or more parts, the two or more parts comprising a first part and a second part;
disposing a source material comprising a plurality of layers of carbon paper between the first part and the second part; and
joining and densifying the first part and the second part by reacting a liquid comprising silicon with the source material to form a joint between the first part and the second part, the joint comprising alternating layers of silicon and silicon carbide.
2 . The method of claim 1 , wherein the first part comprises silicon carbide and the second part comprises silicon carbide.
3 . The method of claim 1 , wherein the first part comprises one or more first channels and the second part comprises one or more second channels, the one or more first channels configured to couple with the one or more second channels.
4 . The method of claim 1 , wherein the first part and the second part are porous.
5 . The method of claim 1 , wherein the joint comprises a ceramic.
6 . The method of claim 1 , wherein the joint has a thickness in a range of 20 μm to 600 μm.
7 . The method of claim 1 , further comprising forming the first part and the second part via at least one of additive manufacturing, pressing, or machining.
8 . The method of claim 1 , wherein the first part and the second part form a hollow structure.
9 . The method of claim 1 , wherein the first part and the second part comprises at least one of a metal, a ceramic, a polymer, or sand.
10 . The method of claim 1 , further comprising forming a heat exchanger from the first part and the second part.
11 . The method of claim 1 , wherein the first part comprises one or more first channels and the second part comprises one or more second channels, the one or more first channels configured to be aligned with the one or more second channels.
12 . The method of claim 1 , wherein the joint has a thickness in a range of 200 μm to 600 μm.
13 . The method of claim 1 , wherein the carbon paper provides a source of carbon for the silicon carbide in the joint.
14 . The method of claim 1 , wherein the liquid comprises copper.
15 . The method of claim 1 , wherein the liquid comprises magnesium.
16 . The method of claim 1 , wherein the liquid comprises aluminum.
17 . The method of claim 1 , wherein a thickness of the joint is based on a number of the plurality of layers of carbon paper.
18 . The method of claim 1 , wherein a thickness of the joint is greater than a thickness of the silicon.
19 . The method of claim 1 , wherein a thickness of the joint is greater than a thickness of the silicon carbide.
20 . The method of claim 1 , wherein the two or more parts comprises a third part, the method comprising:
disposing the source material between the second part and the third part; and
joining and densifying the second part and the third part by reacting the liquid with the source material.