SiC陶瓷与Ti-6Al-4V合金超声波辅助钎焊的润湿结合机制及工艺研究
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摘要
SiC陶瓷和Ti-6Al-4V合金已成为结构材料中重要组成部分。大尺寸复杂陶瓷构件制备困难，同时为满足某些特殊需求或充分发挥材料的性能需要将异种材料组合使用，为此陶瓷/陶瓷、陶瓷/合金等同种材料或异种材料的连接技术显得尤为重要。本文采用超声波辅助钎焊的工艺方法，并采用铝基合金为主要钎料，在大气低温环境下实现了SiC/SiC、SiC/Ti-6Al-4V等接头的钎焊连接。主要研究了铺展润湿行为、氧化膜破碎行为、界面溶蚀行为、界面结构特征及超声波钎焊工艺等。
研究发现超声波激励下液态钎料在固态母材表面的铺展行为存在共性特征。近铺展边缘液态钎料内部的空化效应使得该区域的钎料雾化形成大量的纳米液滴，纳米颗粒的尺寸小于150nm。纳米液滴附着到铺展外延区域的固体表面并发生表面氧化，其分布宽度大约为150μm。同时该区域液态钎料表面的氧化膜破碎发生液态钎料的局部微区铺展，该铺展行为在纳米颗粒所覆盖的固体表面进行。纳米液滴表面的氧化膜使其不能立刻湮灭于钎料内部而呈现出逐步被吞没的现象，并在铺展前沿形成液态钎料/纳米颗粒/固体母材的结构特征。该铺展行为在微观上表现出：铺展于纳米颗粒所覆盖的固体表面，铺展的不同步性，铺展前沿的结合不完整性和逐步性。
通过研究超声波作用液态Al-12Si与固体Ti-6Al-4V的相互作用行为发现固液界面处存在着声致溶蚀行为。该溶蚀行为由尺寸小于25μm的独立的溶蚀坑所构成，溶蚀坑呈近半球形，边缘处存在着斜坡。溶蚀坑的上部被氧化膜所覆盖，并在中心部位存在着一个微小缺口，溶蚀坑底部和侧壁界面处形成Ti_9Al_(23)化合物，斜坡处界面形成Ti_7Al_5Si_(12)化合物。随超声波时间延长或振幅增加，溶蚀坑的密度增加，对溶蚀坑的尺寸影响很小。当振幅增加到6.5μm时，界面处出现由高密度溶蚀坑组成的大面积不规则溶蚀区域。溶蚀坑的形成是由于近界面液态钎料内部空化气泡崩溃时所产生一系列复杂效应造成的。氧化膜的缺口是微射流冲击造成的，它是液态钎料与Ti-6Al-4V相互作用的唯一通道。在高温和声流搅拌作用下，Ti-6Al-4V基体通过氧化膜缺口向液态Al-12Si中过量地快速溶解，最后在溶蚀界面处形成Ti_9Al_(23)化合物。斜坡的形成是空化气泡崩溃作用消失后高温停留阶段的潜流行为造成的，溶解缓慢且界面生成Ti_7Al_5Si_(12)化合物。超声波振幅增大时所出现的大面积不规则溶蚀区域是由于近界面空化气泡簇崩溃所造成的。
针对Al-12Si/Ti-6Al-4V系统在超声波作用后进行保温处理发现，液态Al-12Si沿氧化膜与Ti-6Al-4V界面处对Ti-6Al-4V进行缓慢溶解，氧化膜脱离基体悬浮于液态钎料内部。在超声波4s保温5min就能够使得氧化膜完全脱离基体，同时平直界面处生成Ti_7Al_5Si_(12)化合物，溶蚀坑内部化合物结构变化不大，只是在Ti_9Al_(23)/Ti-6Al-4V界面处生成一层Ti_7Al_5Si_(12)化合物。延长保温时间至8min，界面处近Al-12Si侧生成Ti_9Al_(23)化合物，且最终稳定界面结构为Al-12Si/Ti_9Al_(23)/Ti_7Al_5Si_(12)/Ti-6Al-4V。二次超声波作用能够破碎悬浮于液态钎料内部的氧化膜，但是界面处化合物结构未发生明显变化。Ti-6Al-4V的接头强度可达107.4MPa。
超声波钎焊连接SiC陶瓷时，以纯Al作为填充金属，接头强度可达~65MPa左右，开裂于接头金属内部，但界面连续的Al4C3化合物是接头的潜在威胁。采用Al-12Si钎料时界面平直，不存在化合物，且超声波作用时间对接头强度影响不大，可达95MPa左右。接头开裂接头金属内部和近界面SiC陶瓷内部，未发现界面开裂现象。界面呈现三种结构特征：Al-12Si/SiC、Al-12Si/SiO_2非晶层/SiC、Al-12Si/纳米颗粒/SiO_2非晶层/SiC。非晶层SiO_2是SiC陶瓷经加热后所形成表层氧化膜，其在超声波空蚀效应下可发生分解而去除，而当SiO_2层较厚时，溶蚀处形成了铝硅酸盐Al_2SiO_5化合物。纳米颗粒来自于液态钎料钻缝铺展时所形成，其与超声波诱导铺展时所形成纳米颗粒一致。
在超声波作用下，锌基钎料能够与SiC陶瓷形成良好的润湿结合。采用Zn-8.5Al-1Mg钎料时发现随超声波时间延长接头强度增加，最高可达149MPa左右。超声波作用时间较短时，界面发生开裂，延长超声波时间发现SiC陶瓷内部、界面及近界面金属内部均存在开裂行为。液态钎料中空化气泡的崩溃能够使得SiC表面的SiO_2非晶层被微量溶蚀。随超声波时间的延长，溶蚀程度加剧，从而提高了界面的结合强度。采用三层结构的填充材料实现了具有低膨胀系数的高度复合化SiC陶瓷接头。
采用Al-12Si钎料钎焊连接SiC和Ti-6Al-4V时，由于接头残余应力较大发生SiC陶瓷内部开裂。通过将Sn、Zn、Mg等元素加入Al-12Si钎料中制备了Al-15.5Sn-9.5Si-4.5Zn-0.5Mg钎料，能够使得钎料的凝固温度降低至186℃，主要是因为Sn与Al的固溶度非常小。采用该钎料超声波钎焊连接SiC和Ti-6Al-4V，两侧界面均能够实现良好结合，并且未发生SiC陶瓷开裂现象。在186-561℃冷却温度区间内，钎料处于半固态，具有很好的变形能力，接头两侧金属可以自由收缩，因此可缓解接头的残余应力，并通过数值模拟可以发现采用该钎料时能够显著降低接头残余应力。接头强度可达77.8MPa左右，断裂于近SiC侧接头金属内部和Sn相/SiC陶瓷的界面。
以Al-12Si钎料作为填充合金，超声波钎焊连接Ti-6Al-4V与1060Al时发现，氧化膜与Ti-6Al-4V界面为接头薄弱环节，接头强度大约为34.7MPa。悬浮于接头金属内部的氧化膜以及界面化合物均对接头强度影响不大，大约为68MPa。
SiC ceramic and Ti-6Al-4V alloy have become the important candidates of thestructural materials. However, the poor machining ability for preparing large-size orcomplex ceramic components and the application of the combination of dissimilarmaterials for meeting some special requirements or exerting the good performanceof materials, these problems can be solved by the technologys of joining ceramic tothemselves or alloys. In this study, the joints of SiC/SiC, SiC/Ti-6Al-4V wereachieved by use of ultrasonic-assisted brazing technology in air at a lowertemperature, and aluminium based alloys were used as the main brazing alloys. Thespreading and wetting behaviors, breakage behavior of oxide film, interfacialerosion behaviors, interfcial microstructure and ultrasonic-assisted brazingtechnology were investigated.
The spreading behaviors of liquid brazing alloy on the surface of solid basedmaterials under the excitation of ultrasonic vibration were studied. The brazingalloys and based materials showed little effects on the characteristics ofultrasonic-induced spreading, and this spreading behavior had some commonfeatures. In front of the spreading edge, a layer consisted of high densitynanoparticles formed on the surface of based materials, and this spreading behavioroccurred on the solid surface covered by the nanoparticles. The dimension ofnanoparticle was smaller that150nm, and the width of their distribution area wasabout150μm. The ultrasonic-induced apreading behavior also showed some otherspecial characteristics on the microscopic scale: dyssynchrony of spreadingforefront, partial bonding of the interface at the spreading frontier area,nanoparticles engulfed by the liquid brazing alloy gradually, et al. The nanoparticleswere from the liquid brazing alloy. The cavtition bubbles in the inner of liquidbrazing alloy adjacent the spreading edge collapse suddenly, which induced theliquid brazing alloy atomized and appeard many nanoscale droplets. Thesenanoscale droplets were bonded with the solid surface, and their outer surface wereoxidated when contacting with air. At the same time, the collapse of the cavitationbubbles could broken the surface oxide film that enwrapping the liquid brazing alloyat this corresponding areas, so the liquid brazing alloy would spread forward at themicroscale area. An interface structure of liquid brazing alloy/nanoparticles/solidbased materials was formed at the spreading frontier regions, and the surface oxidefilm of nanoparticle delayed the engulfed process of nanoparticles by the liquidbrazing alloy.
Under the function of ultrasonic, erosion behaviors were found at the interfacebetween liquid Al-12Si and Ti-6Al-4V alloy. The erosion behaviors consisted ofmany isolated erosion pits, and the erosion pits presented a hemispherical shapewith a more gradual slope at the edge. These small erosion pits had non-uniformdimensions, and the maximum diameter was~25μm. The erosion pits was coveredby an incomplete oxide film and there was a tiny notch present in the middle of thisoxide film. Two kinds of IMC form at the pit interface, and they show differentcharacteristics depending on their positions. Ti_9Al_(23)compounds formed at the walland bottom of the pit and Ti_7Al_5Si_(12)compounds formed at the pit edge. The totalnumber and density of the pits increases with prolonging ultrasonic time orincreasing ultrasonic amplitude, but there is no significant change in the range of pitdiameters. However, when the amplitude reached to6.5μm, some large erosion areawith irregular shape appeared on the Ti-6Al-4V surface, which consisted ofhigh-density erosion pits. The formation of erosion pit could be ascribed to thecavitation phenomonen occurred at or near the liquid/solid interface, and manycomplex effects were generated at the small zones during the bubble implosion,including micro-jets, hot spots, high pressure, and acoustic streaming. The impact ofmicro-jets resulted in breakage of the oxide film on the Ti-6Al-4V surface. Theresultant circular notches served as micro-channels for direct interaction betweenliquid Al-Si and solid Ti-6Al-4V. After the micro-channels opened up, localized hotspots and acoustic streaming caused the solid Ti-6Al-4V substrate to excessivelydissolve into the liquid Al-Si alloy at the notch zones, and granular Ti_9Al_(23)particlesformed at the wall and bottom of pits during this extended dissolution process.When the bubble implosion energy dissipated, a slow further dissolution developedalong the interface between the oxide film and Ti-6Al-4V substrate, resulting in agently-sloped region at the pit edges and laminar Ti_7Al_5Si_(12)phases formed at the pitedges. The large irregular erosion areas were induced by the implosion of cavitationbubble clusters.
For Al-12Si/Ti-6Al-4V systerm, a thermostatic treatment process wasperformed after the function of ultrasonic. Ti-6Al-4V alloy dissolved into liquidAl-12Si brazing alloy along the interface between oxide film and Ti-6Al-4V matrix,and the oxide film detached with Ti-6Al-4V and floated in the liquid alloysimultaneously. Holding time for5min after a ultrasonic time of4s could make theoxide film detached the Ti-6Al-4V matrix completely, and Ti_7Al_5Si_(12)compoundsformed at the staight interface. The structure of compounds at the erosion pitsshowed no significant variation, just a layer of Ti_7Al_5Si_(12)compounds formed at theoriginal Ti_9Al_(23)/Ti-6Al-4V interface. Ti_9Al_(23)phases began to form at the inteface and adgacent into the liquid Al-12Si brazing alloy when prolonging the holding timeto8min. For Al-12Si/Ti-6Al-4V interface at620℃, the final steady interfacestructrue was Al-12Si/Ti_9Al_(23)/Ti_7Al_5Si_(12)/Ti-6Al-4V. Second ultrasonic afterthermostatic treatment could break the floating oxide film, but had no effects on thesrtucture of the interfacial compounds.
When ultrasonic-assisted brazing SiC ceramics by filling with pure Al, thestrength of joint could reach to~65MPa and the fracture pathes were in the jointalloy. However, the intermetallic compounds Al4C3at the interface were potentialthreaten. When using the Al-12Si alloy, the interface was straight and no compoundswere found. Ultrasonic time had little effects on the joint strength, which couldreach to95MPa. The fracture paths of joint were in the inner of the joint alloy orthe SiC ceramic adjacent into the interface. The interface of joints showed threekinds of structural characteristics in TEM: Al-12Si/SiC, Al-12Si/SiO_2amorphouslayer/SiC, and Al-12Si/nanoparticle/SiC. The amorphous layer SiO_2was just theoxide film formed on the SiC surface during heating in air, which was decomposedunder the effect of ultrasonic cavitation erosion. Abnormal Al_2SiO_5compoundscould form at the erosion site when the SiO_2layer was much thicker. Thenanoparticles formed in front of the liquid brazing alloy during theultrasonic-assisted filling clearance process, which were consistent with thenanopaticles found during ultrasonic-assisted spreading process.
Ultrasonic-assisted brazed joining SiC ceramic was performed by filling withZn-8.5Al-1Mg brazing alloy. The joint strength increased when prolonging theultrasonic time, and the maximum could reach to~149MPa. When the ultrasonictime was shorter, the fracture paths mainly occurred at the interface. Afterprolonging the ultrasonic time, the fracture paths existed at the interface and in theinner of SiC and joint alloy both adjacent the interface. The collapse of cavitationbubble could also make the SiO_2amorphous layer of SiC surface eroded by theliquid brazing alloy slowly. When prolonging the ultrasonic time, the erosionamount of SiO_2increased, and the joint strength was promoted. A sandwichstructural filler was used joining SiC ceramic and a SiC ceramic joint with lowcoefficient of thermal expansion was obtained.
When SiC ceramic and Ti-6Al-4V alloy were ultrasonic-assisted brazed byfilling with Al-12Si alloy, cracks induced by residual stress could be observed in theinner of SiC ceramic. Newly developed Al-15.5Sn-9.5Si-4.5Zn-0.5Mg brazingalloys were prepared by the addition of element Sn, Zn, Mg, which had a lowsolidus temperature of~183℃, but its liquidus temperatures was also higher to~561℃. An integrated joint was obtained when using the novel filler metals, compared with the inner fractured joint obtained by filling with the common AlSialloy. The novel filler metal was in a semi-solid state at the temperature of183-561℃and showed low deformation resistance, so the shrinkages of the SiCceramic and Ti-6Al-4V alloy had more freedom and a small effect on each otherbefore the solidification of the liquid Sn-rich phases. The results of finite elementcalculation showed the thermal residual stress in the joint was significantlydecreased by use of the novel filler metals. The average shear strength of the jointswas~77.8MPa, the fracture paths occurred in the inner of joint alloy adjacent to theSiC side and at the interfaces between Sn phases and SiC ceramic.
Ultrasonic-assisted brazing of Ti-6Al-4V alloy and Al1060alloy was carriedout by filling with Al-12Si alloy. The oxide film on the Ti-6Al-4V surface beforedetachment with the Ti-6Al-4V showed significantly effects on the joint strenth, andthe joint strength was only~34.7MPa. The oxide film floating in the liquid alloyand the interfacial compounds showed no effects no the joint strength, and the jointstrength could reach to~68MPa.
研究发现超声波激励下液态钎料在固态母材表面的铺展行为存在共性特征。近铺展边缘液态钎料内部的空化效应使得该区域的钎料雾化形成大量的纳米液滴，纳米颗粒的尺寸小于150nm。纳米液滴附着到铺展外延区域的固体表面并发生表面氧化，其分布宽度大约为150μm。同时该区域液态钎料表面的氧化膜破碎发生液态钎料的局部微区铺展，该铺展行为在纳米颗粒所覆盖的固体表面进行。纳米液滴表面的氧化膜使其不能立刻湮灭于钎料内部而呈现出逐步被吞没的现象，并在铺展前沿形成液态钎料/纳米颗粒/固体母材的结构特征。该铺展行为在微观上表现出：铺展于纳米颗粒所覆盖的固体表面，铺展的不同步性，铺展前沿的结合不完整性和逐步性。
通过研究超声波作用液态Al-12Si与固体Ti-6Al-4V的相互作用行为发现固液界面处存在着声致溶蚀行为。该溶蚀行为由尺寸小于25μm的独立的溶蚀坑所构成，溶蚀坑呈近半球形，边缘处存在着斜坡。溶蚀坑的上部被氧化膜所覆盖，并在中心部位存在着一个微小缺口，溶蚀坑底部和侧壁界面处形成Ti_9Al_(23)化合物，斜坡处界面形成Ti_7Al_5Si_(12)化合物。随超声波时间延长或振幅增加，溶蚀坑的密度增加，对溶蚀坑的尺寸影响很小。当振幅增加到6.5μm时，界面处出现由高密度溶蚀坑组成的大面积不规则溶蚀区域。溶蚀坑的形成是由于近界面液态钎料内部空化气泡崩溃时所产生一系列复杂效应造成的。氧化膜的缺口是微射流冲击造成的，它是液态钎料与Ti-6Al-4V相互作用的唯一通道。在高温和声流搅拌作用下，Ti-6Al-4V基体通过氧化膜缺口向液态Al-12Si中过量地快速溶解，最后在溶蚀界面处形成Ti_9Al_(23)化合物。斜坡的形成是空化气泡崩溃作用消失后高温停留阶段的潜流行为造成的，溶解缓慢且界面生成Ti_7Al_5Si_(12)化合物。超声波振幅增大时所出现的大面积不规则溶蚀区域是由于近界面空化气泡簇崩溃所造成的。
针对Al-12Si/Ti-6Al-4V系统在超声波作用后进行保温处理发现，液态Al-12Si沿氧化膜与Ti-6Al-4V界面处对Ti-6Al-4V进行缓慢溶解，氧化膜脱离基体悬浮于液态钎料内部。在超声波4s保温5min就能够使得氧化膜完全脱离基体，同时平直界面处生成Ti_7Al_5Si_(12)化合物，溶蚀坑内部化合物结构变化不大，只是在Ti_9Al_(23)/Ti-6Al-4V界面处生成一层Ti_7Al_5Si_(12)化合物。延长保温时间至8min，界面处近Al-12Si侧生成Ti_9Al_(23)化合物，且最终稳定界面结构为Al-12Si/Ti_9Al_(23)/Ti_7Al_5Si_(12)/Ti-6Al-4V。二次超声波作用能够破碎悬浮于液态钎料内部的氧化膜，但是界面处化合物结构未发生明显变化。Ti-6Al-4V的接头强度可达107.4MPa。
超声波钎焊连接SiC陶瓷时，以纯Al作为填充金属，接头强度可达~65MPa左右，开裂于接头金属内部，但界面连续的Al4C3化合物是接头的潜在威胁。采用Al-12Si钎料时界面平直，不存在化合物，且超声波作用时间对接头强度影响不大，可达95MPa左右。接头开裂接头金属内部和近界面SiC陶瓷内部，未发现界面开裂现象。界面呈现三种结构特征：Al-12Si/SiC、Al-12Si/SiO_2非晶层/SiC、Al-12Si/纳米颗粒/SiO_2非晶层/SiC。非晶层SiO_2是SiC陶瓷经加热后所形成表层氧化膜，其在超声波空蚀效应下可发生分解而去除，而当SiO_2层较厚时，溶蚀处形成了铝硅酸盐Al_2SiO_5化合物。纳米颗粒来自于液态钎料钻缝铺展时所形成，其与超声波诱导铺展时所形成纳米颗粒一致。
在超声波作用下，锌基钎料能够与SiC陶瓷形成良好的润湿结合。采用Zn-8.5Al-1Mg钎料时发现随超声波时间延长接头强度增加，最高可达149MPa左右。超声波作用时间较短时，界面发生开裂，延长超声波时间发现SiC陶瓷内部、界面及近界面金属内部均存在开裂行为。液态钎料中空化气泡的崩溃能够使得SiC表面的SiO_2非晶层被微量溶蚀。随超声波时间的延长，溶蚀程度加剧，从而提高了界面的结合强度。采用三层结构的填充材料实现了具有低膨胀系数的高度复合化SiC陶瓷接头。
采用Al-12Si钎料钎焊连接SiC和Ti-6Al-4V时，由于接头残余应力较大发生SiC陶瓷内部开裂。通过将Sn、Zn、Mg等元素加入Al-12Si钎料中制备了Al-15.5Sn-9.5Si-4.5Zn-0.5Mg钎料，能够使得钎料的凝固温度降低至186℃，主要是因为Sn与Al的固溶度非常小。采用该钎料超声波钎焊连接SiC和Ti-6Al-4V，两侧界面均能够实现良好结合，并且未发生SiC陶瓷开裂现象。在186-561℃冷却温度区间内，钎料处于半固态，具有很好的变形能力，接头两侧金属可以自由收缩，因此可缓解接头的残余应力，并通过数值模拟可以发现采用该钎料时能够显著降低接头残余应力。接头强度可达77.8MPa左右，断裂于近SiC侧接头金属内部和Sn相/SiC陶瓷的界面。
以Al-12Si钎料作为填充合金，超声波钎焊连接Ti-6Al-4V与1060Al时发现，氧化膜与Ti-6Al-4V界面为接头薄弱环节，接头强度大约为34.7MPa。悬浮于接头金属内部的氧化膜以及界面化合物均对接头强度影响不大，大约为68MPa。
SiC ceramic and Ti-6Al-4V alloy have become the important candidates of thestructural materials. However, the poor machining ability for preparing large-size orcomplex ceramic components and the application of the combination of dissimilarmaterials for meeting some special requirements or exerting the good performanceof materials, these problems can be solved by the technologys of joining ceramic tothemselves or alloys. In this study, the joints of SiC/SiC, SiC/Ti-6Al-4V wereachieved by use of ultrasonic-assisted brazing technology in air at a lowertemperature, and aluminium based alloys were used as the main brazing alloys. Thespreading and wetting behaviors, breakage behavior of oxide film, interfacialerosion behaviors, interfcial microstructure and ultrasonic-assisted brazingtechnology were investigated.
The spreading behaviors of liquid brazing alloy on the surface of solid basedmaterials under the excitation of ultrasonic vibration were studied. The brazingalloys and based materials showed little effects on the characteristics ofultrasonic-induced spreading, and this spreading behavior had some commonfeatures. In front of the spreading edge, a layer consisted of high densitynanoparticles formed on the surface of based materials, and this spreading behavioroccurred on the solid surface covered by the nanoparticles. The dimension ofnanoparticle was smaller that150nm, and the width of their distribution area wasabout150μm. The ultrasonic-induced apreading behavior also showed some otherspecial characteristics on the microscopic scale: dyssynchrony of spreadingforefront, partial bonding of the interface at the spreading frontier area,nanoparticles engulfed by the liquid brazing alloy gradually, et al. The nanoparticleswere from the liquid brazing alloy. The cavtition bubbles in the inner of liquidbrazing alloy adjacent the spreading edge collapse suddenly, which induced theliquid brazing alloy atomized and appeard many nanoscale droplets. Thesenanoscale droplets were bonded with the solid surface, and their outer surface wereoxidated when contacting with air. At the same time, the collapse of the cavitationbubbles could broken the surface oxide film that enwrapping the liquid brazing alloyat this corresponding areas, so the liquid brazing alloy would spread forward at themicroscale area. An interface structure of liquid brazing alloy/nanoparticles/solidbased materials was formed at the spreading frontier regions, and the surface oxidefilm of nanoparticle delayed the engulfed process of nanoparticles by the liquidbrazing alloy.
Under the function of ultrasonic, erosion behaviors were found at the interfacebetween liquid Al-12Si and Ti-6Al-4V alloy. The erosion behaviors consisted ofmany isolated erosion pits, and the erosion pits presented a hemispherical shapewith a more gradual slope at the edge. These small erosion pits had non-uniformdimensions, and the maximum diameter was~25μm. The erosion pits was coveredby an incomplete oxide film and there was a tiny notch present in the middle of thisoxide film. Two kinds of IMC form at the pit interface, and they show differentcharacteristics depending on their positions. Ti_9Al_(23)compounds formed at the walland bottom of the pit and Ti_7Al_5Si_(12)compounds formed at the pit edge. The totalnumber and density of the pits increases with prolonging ultrasonic time orincreasing ultrasonic amplitude, but there is no significant change in the range of pitdiameters. However, when the amplitude reached to6.5μm, some large erosion areawith irregular shape appeared on the Ti-6Al-4V surface, which consisted ofhigh-density erosion pits. The formation of erosion pit could be ascribed to thecavitation phenomonen occurred at or near the liquid/solid interface, and manycomplex effects were generated at the small zones during the bubble implosion,including micro-jets, hot spots, high pressure, and acoustic streaming. The impact ofmicro-jets resulted in breakage of the oxide film on the Ti-6Al-4V surface. Theresultant circular notches served as micro-channels for direct interaction betweenliquid Al-Si and solid Ti-6Al-4V. After the micro-channels opened up, localized hotspots and acoustic streaming caused the solid Ti-6Al-4V substrate to excessivelydissolve into the liquid Al-Si alloy at the notch zones, and granular Ti_9Al_(23)particlesformed at the wall and bottom of pits during this extended dissolution process.When the bubble implosion energy dissipated, a slow further dissolution developedalong the interface between the oxide film and Ti-6Al-4V substrate, resulting in agently-sloped region at the pit edges and laminar Ti_7Al_5Si_(12)phases formed at the pitedges. The large irregular erosion areas were induced by the implosion of cavitationbubble clusters.
For Al-12Si/Ti-6Al-4V systerm, a thermostatic treatment process wasperformed after the function of ultrasonic. Ti-6Al-4V alloy dissolved into liquidAl-12Si brazing alloy along the interface between oxide film and Ti-6Al-4V matrix,and the oxide film detached with Ti-6Al-4V and floated in the liquid alloysimultaneously. Holding time for5min after a ultrasonic time of4s could make theoxide film detached the Ti-6Al-4V matrix completely, and Ti_7Al_5Si_(12)compoundsformed at the staight interface. The structure of compounds at the erosion pitsshowed no significant variation, just a layer of Ti_7Al_5Si_(12)compounds formed at theoriginal Ti_9Al_(23)/Ti-6Al-4V interface. Ti_9Al_(23)phases began to form at the inteface and adgacent into the liquid Al-12Si brazing alloy when prolonging the holding timeto8min. For Al-12Si/Ti-6Al-4V interface at620℃, the final steady interfacestructrue was Al-12Si/Ti_9Al_(23)/Ti_7Al_5Si_(12)/Ti-6Al-4V. Second ultrasonic afterthermostatic treatment could break the floating oxide film, but had no effects on thesrtucture of the interfacial compounds.
When ultrasonic-assisted brazing SiC ceramics by filling with pure Al, thestrength of joint could reach to~65MPa and the fracture pathes were in the jointalloy. However, the intermetallic compounds Al4C3at the interface were potentialthreaten. When using the Al-12Si alloy, the interface was straight and no compoundswere found. Ultrasonic time had little effects on the joint strength, which couldreach to95MPa. The fracture paths of joint were in the inner of the joint alloy orthe SiC ceramic adjacent into the interface. The interface of joints showed threekinds of structural characteristics in TEM: Al-12Si/SiC, Al-12Si/SiO_2amorphouslayer/SiC, and Al-12Si/nanoparticle/SiC. The amorphous layer SiO_2was just theoxide film formed on the SiC surface during heating in air, which was decomposedunder the effect of ultrasonic cavitation erosion. Abnormal Al_2SiO_5compoundscould form at the erosion site when the SiO_2layer was much thicker. Thenanoparticles formed in front of the liquid brazing alloy during theultrasonic-assisted filling clearance process, which were consistent with thenanopaticles found during ultrasonic-assisted spreading process.
Ultrasonic-assisted brazed joining SiC ceramic was performed by filling withZn-8.5Al-1Mg brazing alloy. The joint strength increased when prolonging theultrasonic time, and the maximum could reach to~149MPa. When the ultrasonictime was shorter, the fracture paths mainly occurred at the interface. Afterprolonging the ultrasonic time, the fracture paths existed at the interface and in theinner of SiC and joint alloy both adjacent the interface. The collapse of cavitationbubble could also make the SiO_2amorphous layer of SiC surface eroded by theliquid brazing alloy slowly. When prolonging the ultrasonic time, the erosionamount of SiO_2increased, and the joint strength was promoted. A sandwichstructural filler was used joining SiC ceramic and a SiC ceramic joint with lowcoefficient of thermal expansion was obtained.
When SiC ceramic and Ti-6Al-4V alloy were ultrasonic-assisted brazed byfilling with Al-12Si alloy, cracks induced by residual stress could be observed in theinner of SiC ceramic. Newly developed Al-15.5Sn-9.5Si-4.5Zn-0.5Mg brazingalloys were prepared by the addition of element Sn, Zn, Mg, which had a lowsolidus temperature of~183℃, but its liquidus temperatures was also higher to~561℃. An integrated joint was obtained when using the novel filler metals, compared with the inner fractured joint obtained by filling with the common AlSialloy. The novel filler metal was in a semi-solid state at the temperature of183-561℃and showed low deformation resistance, so the shrinkages of the SiCceramic and Ti-6Al-4V alloy had more freedom and a small effect on each otherbefore the solidification of the liquid Sn-rich phases. The results of finite elementcalculation showed the thermal residual stress in the joint was significantlydecreased by use of the novel filler metals. The average shear strength of the jointswas~77.8MPa, the fracture paths occurred in the inner of joint alloy adjacent to theSiC side and at the interfaces between Sn phases and SiC ceramic.
Ultrasonic-assisted brazing of Ti-6Al-4V alloy and Al1060alloy was carriedout by filling with Al-12Si alloy. The oxide film on the Ti-6Al-4V surface beforedetachment with the Ti-6Al-4V showed significantly effects on the joint strenth, andthe joint strength was only~34.7MPa. The oxide film floating in the liquid alloyand the interfacial compounds showed no effects no the joint strength, and the jointstrength could reach to~68MPa.
引文
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