Interfacial Structure and Formation Mechanism of Ultrasonic-assisted Brazed Joint of SiC Ceramics with Al 12Si Filler Metals in Air

Ultrasonic-assisted brazing of SiC ceramics was performed by filling with an Al12Si alloy at a low temperature of 620 °C in air. The interfacial characteristics and formation mechanism were investigated. The joint shear strength reached 84–94 MPa using the ultrasonic time of 2–16 s. The fracture morphology showed that the fracture path initiated and propagated in the joint alloy. The thin film of amorphous SiO2 that formed on the SiC surface was non-uniformly decomposed and diffused into the liquid Al12Si alloy under the cavitation erosion effect of ultrasound. Abnormal isolated blocks of Al2SiO5 compounds formed at the interface between Al12Si and a thicker SiO2 layer formed during the thermal oxidation treatment of the SiC ceramic. The SiO2 layer on the SiC ceramic did not hinder or impair the wetting and bonding process, and a stronger bond could form between Al12Si and SiO2 or SiC in ultrasonic-assisted brazing.