Strength enhancement strategies in brazing Ti alloys to non‐oxide ceramics: An overview of Ti–6Al–4V/Si3N4 joints

Abstract The growing demand for lightweight, heat‐resistant aerospace structures with intricate geometries has driven the integration of non‐oxide ceramics and Ti alloys, addressing the inherent workability and scalability challenges associated with ceramics when used independently. Brazing with eutectic Ag–Cu‐based fillers has emerged as a pivotal technique for fabricating reliable joints between these dissimilar materials. This paper provides a focused overview of strategies to enhance the mechanical reliability of brazed joints between Ti alloys and non‐oxide ceramics, focusing on Ti–6Al–4V (mass%) and Si 3 N 4 . Key challenges influencing joint strength are discussed, including tensile residual stresses from mismatched coefficients of thermal expansion, the limited plastic deformability of Ti‐alloy substrates, and the formation of hard Ti‐based intermetallic compounds. Recent advancements to overcome these challenges are highlighted, such as the use of ductile, non‐reactive interlayers, transient liquid phase bonding, high‐plastic‐deformability braze fillers, and the optimization of both the intrinsic properties of ceramics and joint geometries. This overview provides valuable insights that extend beyond Ti‐alloy/non‐oxide‐ceramic joints, offering strategies applicable to the broader field of dissimilar material bonding.