Interface Phenomena of Co-Sintered Steel-Zirconia Laminates

Abstract

The composite formation of steel and ceramics is especially for medical applications of great interest. By use of the multicomponent tape casting metal-ceramic composite components like bipolar scissors and other surgical instruments can be produced. A coating technology that comes from the paper industry, allows to apply a very thin insulating layer of a few microns between the electrodes consisting of stainless steel. Until now bipolar surgical instruments are produced by mechanical joining of steel and ceramic parts or by spraying a ceramic layer on the steel instruments. This joining steps can lead to stresses in the sensitive ceramic material and leave fine interstices or pores that are not only avoidable with a force and / or tight fit. Both factors are reasons for premature failure of the instrument, even if the materials are not yet at the limits of their resistance. Through the joint shaping by the tape casting and subsequent co-sintering of both materials, a material bond is achieved in addition to the previously existing mechanisms of force and form fit. This optimizes the composite properties and increases the usage time of metal-ceramic layered composites. Special focus is given to the formation of the interface and the associated changes in properties of the individual components of the laminate. These investigantions illustrate the influence of co-manufacturing on the texture of the laminate materials and the formed interface between them. By x-ray diffraction (XRD), field emission scanning electron microscopy (FESEM), energy dispersive X-ray spectroscopy (EDX), x-ray fluorescence analysis (RFA) and thermodynamic calculations (FactSage) of the material bond at the metal-ceramic interface is investigated. In various application areas where steel and zirconia should occur as integral partners, this material combination may be established.