Ultrasonic-based surface patterning and interfacial reaction of ZrO2 ceramics

Abstract

We demonstrate a process to achieve selective surface metallization of ZrO2 ceramics using ultrasound technology in atmospheric environments at 350 °C, which bestows good weldability of ZrO2 to achieve rapid and reliable connections with other metals as well as ceramic materials. The challenge is that brazing or diffusion welding processes to accomplish metallurgical connections for ZrO2 typically require holding at elevated temperatures for minutes to hours, while the selective ultrasonic metallization process requires only a few seconds of processing without the application of covering films or solder resists. In this study, the selected Sn-2Ti alloy could effectively wet and spread on ZrO2 substrate under ultrasonication, and continuous interphase layers were rapidly formed in situ between ZrO2 and Sn-2Ti. The bonding strength for the ZrO2/Sn-2Ti interface was well established with the highest shear strength of 37.1 MPa, and the fracture location occurred at the filler metal. The interfacial reaction layer thickened remarkably with the prolongation of sonication, accompanied by the partial crystallization of amorphous TiO and the formation of irregularly striped Ti11.31Sn3O10 nanocrystals.