Energy field-assisted technology for ceramic/metal joining: a review

Joining ceramics to metals is essential for advanced composite components that combine the superior high-temperature and corrosion resistance, and the mechanical strength of ceramics, with the toughness and machinability of metals, thereby enabling applications in aerospace, electronic packaging, and thermal management. However, significant challenges arise from thermophysical mismatches, particularly coefficient of thermal expansion differences, causing residual stresses, poor interfacial wettability, and uncontrolled brittle phase formation, which compromise joint reliability in traditional joining methods. This review systematically examines multi-energy field-assisted joining technologies for ceramic/metal systems, encompassing single-energy fields (laser, electric, ultrasonic, microwave, and magnetic) and hybrid energy field approaches. It elucidates underlying bonding mechanisms, process optimization strategies, filler/interlayer designs, and engineering applications across diverse materials systems. Laser-assisted techniques deliver localised high-energy input to promote atomic diffusion and phase formation while minimizing heat-affected zones. Electric and ultrasonic fields enable low-temperature or room-temperature bonding through ion migration, interfacial activation, and mechanical interlocking. Microwave and magnetic fields facilitate selective heating and microstructural control, whereas hybrid fields synergistically integrate multiple mechanisms to enhance joint integrity and efficiency. By establishing a comprehensive framework linking mechanisms, optimization, and applications, this review highlights how energy-field-assisted technologies effectively mitigate residual stresses, improve wettability, and suppress detrimental reactions. The analysis provides guidance for selecting and optimizing joining strategies, offering valuable insights for advancing reliable ceramic/metal components in high-end manufacturing.