Ceramic-Metal Joining by a Novel Flame Processing

Economical and efficient heat transfer technologies applicable to high-temperature, high-pressure conditions are a common requirement for advanced fossil energy and other thermal based power generation systems, in which heat is transferred from a heat source into a power cycle working fluid by means of heat exchange components. In addition to high temperature, these components experience high pressure or pressure fluctuations. Alloys with the required thermal and mechanical properties tend to be expensive but still have limited life due to corrosion. In contrast, many ceramic materials have high thermal stability and corrosion resistance that provide the potential to improve the system performance and durability. However, ceramics have low toughness and tension strength and require special engineering, especially for joining with metallic components. Therefore, novel technologies that enable joining ceramics with metals for high performance heat exchange components are urgently needed. With the goal of realizing high performance heat transfer components for modern power generation systems, nGimat Co. proposes the development of an enabling ceramic-metal joining technology based on the recently patented Flame Assisted Flashing Sintering (FAFS). This proprietary technology allows for one step process that enables densification and bonding of ceramic materials onto metal components. A novel ceramic-metal joining composition and structure via FAFS technology will be developed. Processing conditions such as flame temperature, applied field, scanning speed, and ceramic materials composition will be systematically studied to achieve optimal materials properties and bonding strength. Materials properties including ceramic/metal interface structure, hardness, and bonding strength will be tested according to industrial standards. With FAFS fabrication of high performance heat exchange components for power generation systems, nGimat will develop a novel ceramic-metal joining technology. FAFS can also benefit aerospace, nuclear, energy, and manufacturing industries by sintering/bonding ceramic thermal barrier layers onto turbine engine and combustor components. Commercial Applications and Other Benefits: The technology and materials developed will enable the fabrication of high performance heat exchange components for fossil energy power generation systems. FAFS can also be used to sintering/bonding ceramic thermal barrier layers onto turbine engine and combustor components, which can impact a variety of industries including aerospace, nuclear, energy, and manufacturing.