In the present-day industrial sector, the ceramic and metal combination has evolved into one of the crucial processes in a number of high-tech sectors. The combination of ceramics with metals using advanced ceramic brazing techniques which comprise one of its industrial processes has been facilitating the advancement of technology in aerospace, electronic equipment, medical devices and other industries. This article describes the core processes of these advanced technologies and their relevance in the field of manufacturing of Ceramic brazing materials and Ceramic metal composites.
Extended answer: What is Ceramic Brazing?
Ceramic brazing is the joining of metals and ceramics employing a brazed joint where the joined materials are placed in a furnace at a preset high temperature for the filler material to bond the two parts firmly. Ceramic-metal composites have good performance under extreme conditions because ceramics have great thermal insulation and extreme temperature resistance, while metals have great thermal and electrical conductivity and mechanical strength.
Development background of Advanced Ceramic Brazing Techniques
Increased performance requirements have exacerbated the limitations of many older brazing techniques in harsher operational environments. Advanced ceramic brazing techniques do enhance the effectiveness of the join between ceramics and metals but more significantly extend the scope of its use.
Core technology and process flow
Step 1 Select the right Lacquer Brazing Materials
Ceramic bonding adhesives are characterized by a relatively small thickness; metals or alloys that have Silver, Copper or Titanium as the main element can be used as bonding adhesives. Here are a few common Ceramic brazing materials:
Silver based alloys: It is appropriate for low temperature soldering as it possesses excellent wettability and conductivity.
Copper based alloys: It is applied in braze joints which operate under high temperatures and avails great mechanical strength.
Active Brazing Alloys (ABA) : Incorporating small proportions of active elements such as titanium and zirconium into the solder can significantly enhance the wettability of the solder across the ceramic surface.
Step 2 Degreasing and Surface roughening
To make brazing effective, the ceramic part and the metallic component require effective cleaning. They do the following:
Ceramic surface cleaning: remove surface contaminants and oxide layers to improve the wetting effect of the filler metal.
Metal surface treatment: Through plating or chemical treatment, improve the brazing performance of the metal surface.
3. Heating and curing process
In addition to fuel gases, it is best to use an inert atmosphere to avoid metal and flux oxidation when brazing. A common heating cycle comprises the following heating stages:
Heating stage: The filler metal melting temperature is reached at a controlled rate.
Holding stage: A certain temperature is maintained for a certain amount of time so that the surface tension of the metal has no difficulty in penetrating into bond’s metal oxide layer.
Cooling stage: Cooling is controlled to relieve thermal stresses and prevent cracking.
Therefore, it is important to time the heat up time and the cooling time as precisely as possible to optimize the bond strength and durability.
Advantages of Advanced ceramic brazing techniques
High reliability: Compared to Conventional brazing methods, ceramic brazing technology operates more reliably in more complex environments, at more elevated temperatures.
Enhanced mechanical strength: The use of superior quality Ceramic brazing materials and correct braze procedure resulted into joints with good shear and tensile strength.
Wider material compatibility: The advanced ceramic brazing techniques can enable joining of various ceramic and metal materials including alumina, aluminum nitride with stainless steel, and titanium alloy etc.
Excellent air tightness: These technologies ensure high air tightness of the joint when manufacturing vacuum electronics and high pressure sensors.
Application field
1. Aerospace
In the aerospace sector, Ceramic metal composites are used to manufacture engine components and electronic equipment housings to cope with extreme temperature and high-pressure environments.
2. Medical devices
High-performance ceramic brazing technology is widely used in X-ray tubes, surgical equipment and other medical instruments to ensure its high precision and high reliability.
3. Electronics and semiconductors
Advanced ceramic brazing techniques are used to manufacture high-frequency electronic devices and semiconductor packages to provide excellent electrical insulation and thermal conductivity.
4. Industrial automation
In the field of industrial automation, ceramic and metal combinations are used in sensors and high-voltage switches, significantly increasing the durability of equipment.
How to choose the appropriate ceramic brazing technology?
When choosing the appropriate ceramic brazing technology, the following factors need to be considered:
Working environment: Select suitable Ceramic brazing materials according to temperature, pressure and corrosive environment.
Material characteristics: Different ceramic and metal materials have different requirements for brazing, and it is necessary to ensure its compatibility.
Manufacturing process: Advanced process controls and equipment significantly improve joint performance and consistency.
The application of advanced ceramic brazing techniques is very crucial in contemporary industrial production. With quality ceramic brazing materials and high level of workmanship, these technologies have promising applications in aerospace, electronic equipment as well as medical devices.
If you need a ceramic brazing vacuum that operates at high standards, advanced ceramic brazing technology will be able to give you good and constant performance of the products which will make your devices perform well in tough conditions.