Strengthening the ZrC-SiC ceramic and TC4 alloy brazed joint using laser additive manufactured functionally graded material layers

Abstract In order to improve the ZrC-SiC and TC4 brazed joint property, functionally graded material (FGM) layers (two SiC particles reinforced TC4-based composite layers) were designed to relieve the residual stress in the ZrC-SiC and TC4 brazed joint. The FGM layers were fabricated on the TC4 surface using laser additive manufacturing technology before the brazing. Then the TC4 coated with the FGM layers and ZrC-SiC ceramic were brazed using Ti-15Cu-15Ni (wt%) filler. According to the SEM and TEM results, the volume fractions of SiC particles in the FGM layers could reach 20% and 39% respectively. Ti from the braze filler and TC4 reacted with the ZrC-SiC ceramic to form TiC and Ti5Si3 adjacent to the ZrC-SiC ceramic. The shear test results indicate that the adoption of the FGM layers and the brazing temperature both affected the joint property significantly. The FGM layers could benefit the mitigation of coefficient of thermal expansion (CTE) mismatch between the ZrC-SiC and TC4, so that the residual stress caused by the CTE mismatch in the joint was relieved and the joint strength increased. The brazing temperature would affect the microstructure of the brazing seam and then control the joint strength. When the ZrC-SiC ceramic and TC4 coated with the FGM layers were brazed at 970 °C for 10 min, the maximum shear strength could reach 91 MPa, and cracks propagated in the ZrC-SiC ceramic substrate during the shear test.