Finite element method simulation of residual stresses in Al₂O₃–AISI 304 steel joints

Abstract

Thermal residual stresses are very detrimental to the mechanical resistance of metal-ceramic joints and thin metallic foils acting as stress relieving interlayers have been used to reduce their effect. The present work presents finite element method simulations of the residual stress field in Al 2 O 3 -AISI 304 steel joints using interlayers. Different interlayer materials (Ti, Ni, Mo, and Cu) were considered, either separately or in combination. Calculations show that among the different interlayer materials considered, Cu and Ti/Cu are most effective in reducing the thermal stresses and that this role is determined mainly by the ductility of the interlayer material. The calculated results were validated by shear tests performed on real joints obtained by diffusion bonding and it was concluded that residual stresses control the mechanical resistance of the joints.

Anodic bonding

“…The principle of using interlayers is well known for diffusion bonding, where one of the main aims of using interlayers is to reduce the thermal stresses after cooling from the bonding temperature. [105][106][107][108] In anodic bonding thermal stresses are less significant than in diffusion bonding, because of the better matching material combinations and the lower bonding temperatures used.…”

Review Article: recent advances in metal-ceramic brazing

“…The numerical approach, FEM, has been widely used to evaluate residual stresses [11,106,107,108]. Simpler, faster, and much cheaper than the experimental techniques, complete 2-or 3-dimensional stress maps can be obtained.…”

Calculation and experimental determinations of the residual stress distribution in alumina/Ni/alumina and alumina/Ni/nickel alloy systems

“…These methods makes it possible to determine the level of surface stresses at the point of measurement (tensile stress, compressive stress), and they present a good correlation with measurements taken by Xray diffraction (XRD) [21]. Additionally, a variety of analytical [23] and numerical models have been developed to understand and optimize the residual stress state in these materials [11,16,18,22,24]. But rarely they were compared to experimentally measurement with result of classical XRD [16,18] and indentation fracture method.…”