# Patent

## Title
Composite articles made by process for joining bronze part and silicon carbide ceramic part

## Abstract

A process for joining a bronze part and a silicon carbide ceramic part comprising: providing a bronze part, a SiC ceramic part, a Al foil and a Ni foil; placing the SiC ceramic part, the Al foil, the Ni foil, and the bronze part into a mold, the Al foil and the Ni foil located between the SiC ceramic part and the bronze part, the Al foil abutting against the SiC ceramic part, the Ni foil abutting against the bronze part and the Al foil; placing the mold into a chamber of an hot press sintering device, heating the chamber and pressing the bronze part, the SiC ceramic part, the Al foil, and the Ni foil at least until the bronze part, the SiC ceramic part, the Al foil and the Ni foil form a integral composite article.

## Background
CROSS-REFERENCE TO RELATED APPLICATIONS
The disclosures of the three listed applications are incorporated by reference in this instant application. All listed applications have the same assignee.













Ser.


Current


No.
Title
Inventors
Status







13/172,264
PROCESS FOR JOINING STAINLESS 
HSIN-PEI
Patented



STEEL PART AND ZIRCONIA 
CHANG




CERAMIC PART AND COMPOSITE 
et al.




ARTICLES MADE BY SAME




13/172,271
PROCESS FOR JOINING BRASS PART 
HSIN-PEI
Pending



AND SILICON CARBIDE 
CHANG




CERAMIC PART AND COMPOSITE 
et al.




ARTICLES MADE BY SAME




13/172,280
PROCESS FOR JOINING BRASS PART 
HSIN-PEI
Patented



AND SILICON CARBIDE 
CHANG




CERAMIC PART AND COMPOSITE





ARTICLES MADE BY SAME
et al.









BACKGROUND
1. Technical Field
The present disclosure relates to a process for joining a metal part and a ceramic part, especially to a process for joining a bronze part and a silicon carbide ceramic part, and a composite article made by the process.
2. Description of the Related Art
It is desirable to join bronze parts and silicon carbide ceramic parts. A typical process for joining bronze and silicon carbide ceramic is by positioning physically separate nickel foil or molybdenum foil as intermediate layer between bronze and silicon carbide ceramic. However, the foil retains its separate nature through manufacturing and in the final product and does not chemically interact with the bronze or silicon carbide ceramic. Furthermore, in case of using physically separate nickel foil, due to great difference between the coefficients of heat expansion of the silicon carbide ceramic and the nickel foil, the ceramic/nickel interface has large thermal stress, thus, the bond between the bronze and the silicon carbide ceramic via nickel foil is not as stable as desired. In case of using physically separate molybdenum foil, due to having a relatively low reaction activity, it is difficult for silicon carbide ceramic and molybdenum foil to inter-diffuse into each other, enhancing the difficulty of bonding.
Therefore, there is room for improvement within the art.



BRIEF DESCRIPTION OF THE DRAWINGS
Many aspects of the embodiments can be better understood with reference to the following drawings. The components in the drawings are not necessarily drawn to scale, the emphasis instead being placed upon clearly illustrating the principles of the exemplary process for joining bronze part and silicon carbide ceramic part, and composite article made by the process. Moreover, in the drawings like reference numerals designate corresponding parts throughout the several views. Wherever possible, the same reference numbers are used throughout the drawings to refer to the same or like elements of an embodiment.
FIG. 1 is a schematic cross-sectional view of an example of a hot press sintering device for implementing the present process.
FIG. 2 is a cross-sectional view of an exemplary embodiment of the present article made by the present process.



DETAILED DESCRIPTION
Referring to FIG. 1, an exemplary process for joining a bronze part and a silicon carbide ceramic part, may includes the following steps:
A silicon carbide (SiC) ceramic part 20, a aluminum (Al) foil 40, an nickel (Ni) foil 50 and a bronze part 30 are provided. The Al foil 40 and the Ni foil 50 are used as a joining medium between the SiC ceramic part 20 and the bronze part 30. Each of the Al foil 40 and the Ni foil 50 has a thickness in a range from about 0.1 millimeter (mm) to about 0.5 mm.
The SiC ceramic part 20, the bronze part 30, the Al foil 40 and the Ni foil 50 are pretreated. The pretreatment may include the step of polishing the surfaces of The SiC ceramic part 20, the bronze part 30, the Al foil 40 and the Ni foil 50 by silicon carbide (SiC) sandpaper to produce smooth surfaces. Then, the SiC ceramic part 20, the bronze part 30, the Al foil 40 and the Ni foil 50 are cleaned by placing them into an organic solution to remove grease from their surfaces. The organic solution can be ethanol, and/or other organic solvents. Then, the SiC ceramic part 20, the bronze part 30, the Al foil 40 and the Ni foil 50 are rinsed with water and dried.
A clamping mold 70 is used to hold the SiC ceramic part 20, the bronze part 30, the Al foil 40 and the Ni foil 50. The clamping mold 70 includes a pressing board 72, a corresponding supporting board 74 and a receiving board 76. The receiving board 76 defines a cavity 762 running through the upper/bottom surface to receive the SiC ceramic part 20, the bronze part 30, the Al foil 40 and the Ni foil 50. The pressing board 72 and the corresponding supporting board 74 extend towards the cavity 762 from opposing directions and can be moved relative to the cavity 762 by a driving system such as hydraulic pressure system. The SiC ceramic part 20, the Al foil 40, the Ni foil 50 and the bronze part 30 are placed into the cavity 762 and clamped by the pressing board 72 and the corresponding supporting board 74. The Al foil 40 and the Ni foil 50 are inserted between the SiC ceramic part 20 and the bronze part 30. The Al foil 40 abuts against the SiC ceramic part 20, the Ni foil 50 abuts against the bronze part 30. The pressing board 72 and the corresponding supporting board 74 from two opposite sides, bringing the surfaces of the parts to be joined into tight contact, for compressing the SiC ceramic part 20, the Al foil 40, the Ni foil 50 and the bronze part 30.
A hot press sintering device 100 including a chamber 101 is provided. The clamping mold 70 is placed into the chamber 101. The vacuum level inside the chamber 101 is set to about 10−3 Pa to about 9×10−3 Pa. Argon (Ar) is fed into the chamber 101 to maintain the chamber 101 pressure in a range of about 0.3 MPa-0.6 MPa. The pressing board 72 and the corresponding supporting board 74 press toward each other at about 10 MPa to firmly clamp the SiC ceramic part 20 and the bronze part 30. Then, the chamber 101 is heated at a rate of about 1 degrees Celsius per minute (° C./min)-20° C./min. When the temperature of the chamber 101 reaches to about 300° C., the clamping pressure applied by the boards 72,74 steadily increases, until the temperature of the chamber 101 reaches to about 680° C.-980° C., and the clamping pressure reaches to about 10 MPa-50 MPa. The pressure and heat are maintained in their respective peak ranges for about 40 min-80 min, so that the Al foil 40 and the Ni foil 50 will chemically interact with each other, and the Al foil 40 chemically interacts with the SiC ceramic part 20, and the Ni foil 50 chemically interacts with the bronze part 30. Accordingly, the SiC ceramic part 20 and the bronze part 30 are connected by the Al foil 40 and the Ni foil 50 to form a composite article 10. The composite article 10 is removed after the chamber 101 is cooled.
Referring to FIG. 2, in the process of making the composite article 10, the Al foil 40 and the Ni foil 50 act as intermediate layers to form a connecting layer 80 that connects the SiC ceramic part 20 and the bronze part 30. The heat expansion rate of SiC ceramic part 20 is approximately equal to that of the Al foil 40, thus the SiC ceramic part 20 can substantially connect with the Al foil 40. The heat expansion rate of the bronze part 30 is approximately equal to that of the Ni foil 50, thus the bronze part 30 can substantially connect to the Ni foil 50. Furthermore, the combination of the Al foil 40 and the Ni foil 50 to form the connecting layer 80 results in a connecting layer 80 having a rate of heat expansion that gradually changes from one end to the other. Therefore, the SiC ceramic part 20 is securely connected with the bronze part 30 and more able to cope with temperature changes.
The composite article 10 manufactured by the present process includes the SiC ceramic part 20, the bronze part 30 and a multi-layered connecting layer 80 connecting the SiC ceramic part 20 to the Bronze part 30. The connecting layer 80 is formed by placing the Al foil 40 and the Ni foil 50 between the SiC ceramic part 20 and the Bronze part 30, and then heating and pressing the SiC ceramic part 20 and the bronze part 30 as previously described. The various layers of the connecting layer 80 result from differing chemical interactions between the bronze part 30, Al foil 40, Ni foil 50, and SiC ceramic part 20. In particular, the connecting layer 80 includes:
a) a first transition layer 81: The first transition layer 81 mainly includes chemical compounds comprising Al element and C element, and chemical compounds comprising Si element and Al element, such as Al2C3, etc. The compounds result from chemical reactions between adjacent portions of the SiC ceramic part 20 and Al foil 40;
b) a Al layer 82: The Al layer 82 results from portions of the Al foil 40 that do not chemically react with either the SiC ceramic part 20 or the Ni foil 50;
c) a second transition layer 83: The second transition layer 83 is located between the Al layer 82 and the Ni layer 84. The second transition layer 83 mainly includes chemical compounds comprising Al element and Ni element, and Ni with Al solid solutions. The compounds and solutions result from chemical reactions between adjacent portions to the Al foil 40 and Ni foil 50;
d) an Ni layer 84: The Ni layer 84 results from portions of the Ni foil 50 that do not chemically react with either the Al foil 40 or the bronze part 30; and
e) a third transition layer 85: The third transition layer 85 is located between the Ni layer 84 and the bronze layer 30 and connects the Ni layer 84 and the bronze layer 30. The third transition layer 85 mainly includes chemical compounds comprising Ni element and Cu element, and Ni with Cu solid solutions. The third transition layer 85 further includes some chemical compounds comprising Ni element and Sn element, and Ni with Sn solid solutions. Because the bronze layer 30 generally includes tin (Sn) element and the ratio of the Zn element is about below 10%. The compounds and solutions result from chemical reactions between adjacent portions to the Ni layer 84 and the bronze layer 30.
The thermal expansion rate of the connecting layer 80 gradually changes from a value close to that of the SiC ceramic part 20 (in the area of the first transition layer 81) to a value close to that of bronze part 30 (in the area of the third transition layer 85). This results in a composite article 10 well suited to temperature changes due to the gradual, rather than abrupt, changes in its internal thermal expansion rates.
Furthermore, the connecting layer 80 of the composite article 10 has no cracks or apertures, and has a smooth surface. The composite article 10 has high hardness, high temperature resistance, corrosion resistance abrasion resistance, shear strength in a range from about 50 MPa to about 80 MPa, and tension strength in a range from about 60 MPa to about 100 MPa.
It is to be understood that even though numerous characteristics and advantages of the present embodiments have been set forth in the foregoing description, together with details of assemblies and functions of various embodiments, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size, and arrangement of parts within the principles of the present invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.

## Claims

1. A composite article, comprising:
a SiC ceramic part,
a bronze part, and
a connecting layer that connects the SiC ceramic part to the bronze part, wherein the connecting layer is formed by placing a Al foil and a Ni foil between the SiC ceramic part and the bronze part with the Al foil abutting the SiC ceramic part and the Ni foil abutting the bronze part, then heating and pressing the SiC ceramic part, the bronze part, the Al foil and the Ni foil;
wherein the connecting layer includes a first transition layer adjacent the SiC part, a Al layer, a second transition layer, a Ni layer, and a third transition layer adjacent the bronze part, and in that order; the first transition layer located between the SiC ceramic part and the Al layer mainly includes compounds comprising Al element and C element; and the thermal expansion rate of the connecting layer gradually changes from that of the first transition layer to that of the third transition layer.

2. The composite article as claimed in claim 1, wherein the compounds include Al2C3.

3. The composite article as claimed in claim 1, wherein the second transition layer located between the Al layer and the Ni layer mainly includes compounds comprised of Al element and Ni element, and Ni—Al alloy solid solutions.

4. The composite article as claimed in claim 1, wherein the third transition layer located between the Ni layer and the bronze part mainly includes Ni—Cu solid solutions.

5. The composite article as claimed in claim 4, wherein the third transition layer further includes a Ni element and Sn element, and Ni—Sn solid solutions.