Co-sintering of a ceramic-metal bilayer: Coupled experimental, analytical and numerical approaches

The co-sintering behavior of a ceramic-metal bilayer is carefully investigated. This bilayer is composed of a gold film deposited by screen-printing on a silica-based low-temperature cofired ceramic (LTCC) layer. First, behaviors of both materials in free sintering are finely characterized. LTCC exhibits a viscous flow sintering mechanism, whereas the densification mechanism of gold is controlled by grain boundary diffusion (with an identified apparent activation energy of 101 ± 15 kJ mol −1 ). Free sintering of gold is also marked by a two-step densification process due to its large bimodal particle size distribution. A methodology is proposed to estimate gold viscosity at high temperatures directly from raw experimental data in free sintering, without performing dedicated mechanical characterizations. Based on the constitutive laws identified for LTCC and gold materials, analytical and numerical models of the bilayer co-sintering process are built. During co-sintering, stresses generated by densification kinetic mismatch between gold and LTCC are progressively relaxed by camber phenomenon. Calculated evolutions of camber in co-sintering are compared to curvature monitoring by ombroscopy. Finite element simulation in 3D fits well with the experimental data, whereas the analytical solution strongly underestimates camber rates. This shows that the simplified numerical approach suggested here leads to a robust numerical model, faithfully describing thermomechanical interactions occurring in co-sintering within the ceramic-metal bilayer.