Ceramic constructional components are quite extensively required for operation of high-temperature nuclear reactors. Functional ceramics, in addition to constructional ceramics, are increasingly coming into the focus of research. Ceramic materials are predestined for use at high temperatures and in corrosive atmospheres. Modification of silicon carbide (SiC) by targeted doping, for instance, produces a suitable material for the production of heating conductors and thermoelectric generators. As a construction material, silicon carbide (SiC) is especially interesting due to its very good thermal, mechanical and radiological properties. SiC, furthermore, performs well when activated by neutron irradiation, with the induced activation subsiding after only a few hours (Hurtado, 1996). This property vector makes it an ideal starting material for use in a wide range of functional elements in high-temperature power engineering, particularly in high-temperature nuclear reactor engineering (e.g. V/HTR) including thermochemical plants for hydrogen generation or Synfuel production. In principle, it is possible to produce all-ceramic assemblies consisting of a thermoelectric generator and a sensor that can provide reliable measurement signals under extreme conditions in the high-temperature range without external power supply. This paper explains the feasibility of laser-joining such modified non-oxide ceramics, how to make electrically conductive joints, and thus, how to design complex assemblies. The parameters required for an optimal laser process to join ceramic materials were determined in extensive preliminary experiments. These investigations focused on the specific electrical resistances and optical properties. Specifically developed brazing fillers were fine-tuned so that the joints of the ceramics improved in terms of their physical interactions, chemical reactions and ability to bond or key chemically and mechanically with the ceramic surfaces. Thereby, the electrical conductivity required could be maintained up to temperatures above 950°C. Laser processing was carried out in a high-performance laser laboratory with diode lasers utilized in power ranges from 3kW to 10kW (continuous wave – cw). The measured four-point bending strength of the joined samples was between 120 and 170MPa (approx. 60% that of the starting material). No significant electrical conductivity drop was found in the joint area during resistance measurements. The results underline that the high-temperature laser joining technology used here is well-suited to provide electrically conductive ceramics with high-temperature resistant properties. This opens up new possibilities for the cost-effective and efficient manufacture of an entire range of high-temperature sensors as required in power engineering and, above all, in the field of high-temperature reactor engineering.
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