Joining of SiC, alumina, and mullite by the Refractory Metal—Wrap pressure‐less process

The aim of this work was to discuss the suitability of the joining process called “RMWrap” (RM = Refractory Metals, ie, Mo, Nb, Ta, Zr) as a pressure-less and tailorable technique to join several different ceramics such as SiC, alumina, and mullite (3Al2O3.2SiO2). In the RM-Wrap joining technique the refractory metal foil is used as a wrap containing one or more silicon foils. It is performed at 1450°C, under flowing argon, and the resulting joining materials are in situ formed composites made of refractory metal disilicides (MoSi2, NbSi2, TaSi2, or ZrSi2) embedded in a siliconrich matrix; their coefficient of thermal expansion has been calculated and the Laser Flash Method was used to measure the thermal diffusivity of one of them (MoSi2/Si) in 25°C-1000°C range, then to calculate its thermal conductivity. All the obtained joints are uniform, continuous, and crack free. Some preliminary oxidation tests were carried out on all joints at 1100°C, 6 hours in air, giving unchanged morphology of the interface and the joining materials itself; the joint strength of RM-Wrap joined SiC was measured at room temperature using three different mechanical tests: (a) single lap (SL), (b) single lap off-set (SLO) and (c) torsion on hourglass-shaped samples (THG) (on Mo-wrap joined SiC).