Abstract
3 mol% yttria-stabilized zirconia (3YSZ) and a nickel-based superalloy (GH3128) were robustly joined in seconds using a Cu interlayer at 1000 °C under the application of an electric field. The shear strength of the joints reached 190 ± 6 MPa within 2 s of energization and increased to 250 ± 15 MPa with the extension of the energization time to 30 s. The electric field-induced electrochemical reactions greatly accelerated atomic interdiffusion, generated Cu−Zr eutectic liquid at the interface and enabled the interfacial gap to be rapidly filled due to the good wettability of 3YSZ by the melt, thus yielding the strong joints in seconds. The key joining parameters (current density, time and temperature) were investigated and the correlations between interfacial structural evolution and fracture characteristics were addressed. This work provides a reliable method for ultrafast and robust joining of zirconia to metals.
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