An in situ 3D core–sheath interlayer utilized for reinforcing a WC–Co/3Cr13 brazed joint

Abstract Large residual stress induced by significant difference in the coefficient of thermal expansion compromises the mechanical performance of a brazed joint between the WC–Co cemented carbide (YG20) and 3Cr13 stainless steel in a cutting tool of shield machine. In this study, a melamine formaldehyde foam precursor was utilized to produce a 3D hollow carbon foam (HCF) used as interlayer through a high‐temperature carbonization process to aid in the brazing process of YG20 and 3Cr13. First, the morphology and microstructure of the HCF interlayer were revealed as a defect‐rich carbon shell with a hollow structure. Afterward, the effects of introducing the as‐prepared HCF interlayer on the joint microstructure and shear performance were investigated. Results indicate that the HCF interlayer contributed to phase homogenization and, moreover, the residual stress relieving through in situ forming a core (metallic matrix)–sheath (ceramic shell) structure. This method outperformed the direct brazing approach without using an interlayer, with a 41% increase in the joint shear strength due to the synergistic strengthening mechanism of the HCF through residual stress reliving and joint seam toughening. Based on the results, in spite of the residual stress, the fast load transfer and the compensation from the matrix core to the ceramic sheath are responsible for the improved mechanical performance of the joint.