Ceramic to ceramic joint and associated methods
View Patent ↗The present invention provides a ceramic to ceramic joint and methods for making such a joint. Generally, the joint includes a first ceramic part and a second ceramic part, wherein the first and second ceramic parts each include a ceramic-carbide or a ceramic-nitride material. In some cases, an aluminum-initiated joint region joins the first and second ceramic parts. This joint region typically includes chemical species from the first and second ceramic parts that have diffused into the joint region. Additionally, the first and second ceramic parts each typically include a joint diffusion zone that is disposed adjacent to the joint region and which includes aluminum species from the joint region that have diffused into the joint diffusion zone. Other implementations are also described.
1. A ceramic to ceramic joint comprising:
a first ceramic part, wherein the first ceramic part is a direct-sintered ceramic carbide;
a second ceramic part, wherein the second ceramic part is a direct-sintered ceramic carbide; and
an aluminum-initiated joint region formed from an aluminum joint initiator having a thickness between about 5 μm and about 1270 μm, said joint region joining the first and second ceramic parts, wherein the joint region comprises chemical species from the first and second ceramic parts diffused within the joint region, wherein the first ceramic part comprises a first joint diffusion zone disposed adjacent to the joint region which comprises aluminum initiator species from the joint region diffused within the first joint diffusion zone, and wherein the second ceramic part comprises a second joint diffusion zone disposed adjacent to the joint region which comprises aluminum initiator species from the joint region diffused within the second joint diffusion zone, wherein the amount of aluminum initiator species diffused into the first and second joint diffusion zones is greater than the amount of free aluminum initiator species remaining in the joint region.
2. The ceramic to ceramic joint according to claim 1 , wherein the joint region has a joint strength greater than 50% of a bulk strength of the first and second ceramic parts.
3. The ceramic to ceramic joint according to claim 1 , wherein the joint region has a joint strength greater than 60% of a bulk strength of the first and second ceramic parts.
4. The ceramic to ceramic joint according to claim 1 , wherein the joint region has a joint strength greater than 70% of a bulk strength of the first and second ceramic parts.
5. The ceramic to ceramic joint according to claim 1 , wherein the joint region has a joint strength greater than 80% of a bulk strength of the first and second ceramic parts.
6. The ceramic to ceramic joint according to claim 1 , wherein the joint region has a joint strength greater than 90% of a bulk strength of the first and second ceramic parts.
7. The ceramic to ceramic joint according to claim 1 , wherein the joint region has a joint strength greater than or equal to a bulk strength of the first and second ceramic parts.
8. A ceramic to ceramic joint comprising:
a first ceramic part, wherein the first ceramic part is a direct-sintered ceramic carbide;
a second ceramic part, wherein the second ceramic part is a direct-sintered ceramic carbide; and
an aluminum-initiated joint region formed from an aluminum joint initiator having a thickness between about 5 μm and about 1270 μm said joint region joining the first and second ceramic parts characterized by diffusion and counter-diffusion of chemical species between the joint region and the adjoining first and second ceramic parts, wherein the joint region has a joint strength greater than 50% of a bulk strength of the first and second ceramic parts, wherein the amount of aluminum initiator species diffused into the first and second joint diffusion zones is greater than the amount of free aluminum initiator species remaining in the joint region.
9. The ceramic to ceramic joint according to claim 8 , wherein the joint region has a joint strength greater than 60% of the bulk strength of the first and second ceramic parts.
10. The ceramic to ceramic joint according to claim 8 , wherein the joint region has a joint strength greater than 70% of the bulk strength of the first and second ceramic parts.
11. The ceramic to ceramic joint according to claim 8 , wherein the joint region has a joint strength greater than 80% of the bulk strength of the first and second ceramic parts.
12. The ceramic to ceramic joint according to claim 8 , wherein the joint region has a joint strength greater than 90% of the bulk strength of the first and second ceramic parts.
13. The ceramic to ceramic joint according to claim 8 , wherein the joint region has a joint strength equal to the bulk strength of the first and second ceramic parts.
14. The ceramic to ceramic joint according to claim 1 , wherein there is less than 10 mole % of the aluminum initiator species remaining in the joint region.
15. The ceramic to ceramic joint according to claim 1 , wherein there is less than 20 mole % of the aluminum initiator species remaining in the joint region.
16. The ceramic to ceramic joint according to claim 1 , wherein there is less than 30 mole % of the aluminum initiator species remaining in the joint region.
17. The ceramic to ceramic joint according to claim 1 , wherein there is less than 40 mole % of the aluminum initiator species remaining in the joint region.
18. The ceramic to ceramic joint according to claim 1 , wherein the first joint diffusion zone, the second joint diffusion zone, and the joint region comprise multiple ceramic phases formed from the aluminum initiator species and chemical species from the first and second ceramic parts.
19. The ceramic to ceramic joint according to claim 1 , wherein the aluminum-initiated joint region is formed from undoped aluminum.
20. The ceramic to ceramic joint according to claim 1 , wherein the ceramic to ceramic joint functions at a temperature higher than about 670° C.
21. The ceramic to ceramic joint according to claim 1 , wherein, wherein the ceramic to ceramic joint functions at a temperature higher than about 900° C.
22. The ceramic to ceramic joint according to claim 1 , wherein, wherein the ceramic to ceramic joint functions at a temperature higher than about 1,000° C.
23. The ceramic to ceramic joint according to claim 1 , wherein, wherein the ceramic to ceramic joint functions at a temperature higher than about 1,500° C.
24. The ceramic to ceramic joint according to claim 8 , wherein there is less than 10 mole % of the aluminum initiator species remaining in the joint region.
25. The ceramic to ceramic joint according to claim 8 , wherein there is less than 20 mole % of the aluminum initiator species remaining in the joint region.
26. The ceramic to ceramic joint according to claim 8 , wherein there is less than 30 mole % of the aluminum initiator species remaining in the joint region.
27. The ceramic to ceramic joint according to claim 8 , wherein there is less than 40 mole % of the aluminum initiator species remaining in the joint region.
28. The ceramic to ceramic joint according to claim 8 , wherein the first joint diffusion zone, the second joint diffusion zone, and the joint region comprise multiple ceramic phases formed from the aluminum initiator species and chemical species from the first and second ceramic parts.
29. The ceramic to ceramic joint according to claim 8 , wherein the aluminum-initiated joint region is formed from undoped aluminum.
30. The ceramic to ceramic joint according to claim 8 , wherein the ceramic to ceramic joint functions at a temperature higher than about 670° C.
31. The ceramic to ceramic joint according to claim 8 , wherein, wherein the ceramic to ceramic joint functions at a temperature higher than about 900° C.
32. The ceramic to ceramic joint according to claim 8 , wherein, wherein the ceramic to ceramic joint functions at a temperature higher than about 1,000° C.
33. The ceramic to ceramic joint according to claim 8 , wherein, wherein the ceramic to ceramic joint functions at a temperature higher than about 1,500° C.
34. A ceramic to ceramic joint comprising:
a first ceramic part, wherein the first ceramic part is a direct-sintered ceramic carbide;
a second ceramic part, wherein the second ceramic part is a direct-sintered ceramic carbide; and
an aluminum-initiated joint region having a thickness of about 3 μm to about 5 μm joining the first and second ceramic parts, wherein the joint region comprises chemical species from the first and second ceramic parts diffused within the joint region, wherein the first ceramic part comprises a first joint diffusion zone disposed adjacent to the joint region which comprises aluminum initiator species from the joint region diffused within the first joint diffusion zone, and wherein the second ceramic part comprises a second joint diffusion zone disposed adjacent to the joint region which comprises aluminum initiator species from the joint region diffused within the second joint diffusion zone, wherein the amount of aluminum initiator species diffused into the first and second joint diffusion zones is greater than the amount of free aluminum initiator species remaining in the joint region.