Joining ceramic to metal using a powder metallurgy method for high temperature applications

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Fecralloy was successfully joined to calcia stabilised zirconia (CSZ) using a mixture of Fe, Cr and Al powders as a brazing filler and a screen printing and powder metallurgy method. The joining process was achieved at 1000 °C for 5 h in vacuum. During the joining process the filler wetted the surfaces of the CSZ and the Fercalloy foil, and formed a Fe(Cr, Al) alloy. The joint produced using the filler of (Fe-30Cr-5Al)-0.06 (Y2O3) (wt.%) showed good thermal stability and good thermal cycling oxidation resistance at temperatures up to 850 °C in air, even though the joint contained some porosity.

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