Abstract
(La0.2Nd0.2Sm0.2Gd0.2Yb0.2)2Zr2O7 high-entropy ceramic (HEC) and 3 mol% yttria-stabilized zirconia were directly joined in seconds using an innovative pressure-assisted flash joining technique. An optimized shear strength of 26 ± 3 MPa was obtained at 1200 °C under uniaxial pressure of 9 MPa in 30 s. The contact resistance at the interface was found to induce intense local Joule heating, which accelerated interfacial mass transport and the joining process. However, this local heating effect also led to segregation and precipitation of the HEC near the interface, forming large La/Yb-rich rare-earth zirconate grains and intergranular pores. Increasing the pressure inhibited these issues by lowering the contact resistance, suppressing grain growth, and promoting grain sliding, rearrangement, and coalescence of grain boundaries. The proposed mechanism, based on the local heating effect, provides new insights into flash joining, highlighting the critical role of this phenomenon in triggering thermal runaway and mass transport.
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