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Ceramics International
journal homepage: www.elsevier.com/locate/ceramint
art ic l e i nf o a b s t r a c t
Article history: Aluminum alloys are light-weight and one of the most interesting material solutions to optimize the
Received 3 May 2016 strength/weight ratio to reduce car weight; however they are also relatively soft and therefore cannot be
Received in revised form used for intensive wear applications. We developed an aluminum alloy part combined with hard and
5 July 2016
wear-resistant Al2O3-based ceramic plates on the surface for demanding mechanical parts for automotive
Accepted 5 July 2016
industry such as disc brakes.
Available online 7 July 2016
Tribological tests of various engineering ceramic materials were performed in order to nd a ceramic
Keywords: material with a combination of coefcient, wear resistance and thermal energy dissipation for the car
Ceramic brakes. Al2O3-based ceramic showed promising properties, as well as being cost effective.
Wear resistant
Two different approaches to braze ceramic on aluminum were investigated. A two-step brazing
Soldering
process using Cu-Sn-Ti-Zr ller alloy and a single step ultrasonic active soldering with Sn-Ag-Ti ller
Brazing
Aluminum brake disc alloy. Larger areas of aluminum could be covered with a segmented brake design in which many ceramic
plates were joined surface. Comparable tribological properties to those of the bulk ceramic material were
achieved.
& 2016 Elsevier Ltd and Techna Group S.r.l. All rights reserved.
http://dx.doi.org/10.1016/j.ceramint.2016.07.035
0272-8842/& 2016 Elsevier Ltd and Techna Group S.r.l. All rights reserved.
15740 L. Gorjan et al. / Ceramics International 42 (2016) 1573915746
GS220 Solder alloy 92Sn 3Ag 3Ti (Ce, Ga) 220 230
Diabraze Braze alloy 74Cu 14.5Sn 10Ti 1.5Zr 868 925
2. Experimental
2.1. Concept design alloy with the composition of 92Sn3Ag3Ti ( Ce, Ga). It has a
melting range of 220230 C and it contains titanium as an active
The idea behind the project was to use an aluminum alloy to element.
make a lightweight brake disc body and cover the wear area with a Diabraze is Cu-Sn-based active ller metal and was chosen
hard and wear-resistant material. The concept is schematically because of its high strength and ability to wet and react with
shown in Fig. 1. Cast aluminum alloy is used for a body onto which materials which are typically difcult to bond by brazing [2224].
harder and wear resistant ceramic material is brazed. The good bonding is due to the large amount of the active ele-
ments Ti and Zr. Diabraze has been already successfully used to
2.2. Materials join diamond and boron nitride ceramics with steel substrate
[22,24].
Materials used in our research are listed in Table 1 together
with their basic properties. Two different aluminum alloys were 2.3. Joining and machining the samples
used - A380 and A356, which are widely used in automotive and
other industries. Solid sample parts were cast at Fagor Ederlan, Two different approaches to bond wear resistant material on
Spain, using a low-pressure aluminum casting process. top of aluminum part were considered and are sketched in Fig. 2.
Several technical ceramic materials were considered for the top a) Two-step vacuum brazing was made using the Diabraze
layer. After the tribological tests of different bulk ceramic samples CuSnTiZr braze metal (Fig. 2a). First, the alloy slurry was applied to
we focused on Al2O3 ceramic. Material marked as Al2O3 was pre- the ceramic surface and processed at 900 C in vacuum in order to
pared from commercial 99.7% alumina powder (Granalox NM9922, melt the ller metal and make a strong bonding with the ceramic
Nabaltec, Germany), pressed and sintered at 1620 C for 2 h in air. surface. After the end of this metallization step, the samples were
Materials used for joining wear resistant layers to aluminum put on the top of aluminum alloy substrate so that the metalli-
alloy substrates are listed in Table 2. zation layer was in direct contact with the aluminum alloy. The
GS220 (MBR Electronics, Switzerland) is an active soldering samples were then heated in vacuum to 555 C for 15 min. This
L. Gorjan et al. / Ceramics International 42 (2016) 1573915746 15741
Fig. 2. Different approaches to apply hard material on the surface of aluminum alloy part by brazing or soldering.
temperature is actually far below the solidus temperature of the resistance of the joint is lower, due to the relatively low melting
braze alloy (868 C) because we are limited by the melting point of point of the solder alloy. To further reduce the thermal stresses we
the aluminum alloy substrate, which has a melting range of 555 also explored the so called segmented design, where large surface
615 C. However holding at the solidus temperature of the sub- of aluminum is covered by multiple smaller pieces of ceramic.
strate, the braze alloy reacts with the aluminum, forming a bond. After joining the surfaces were ground by diamond wheel in
The joining procedure was developed and made by Listemann order to achieve the proper atness required for the tribological
Technology AG, Liechtenstein. tests. Final surface roughness Ra was 1.1 mm as measured by a
The braze alloy has a relatively high melting point and thus Hommel tester T500 (Hommelwerke, Germany).
guarantees temperature resistance of the joint. On the other hand
the process involves relatively high processing temperatures 2.4. Characterization
which causes large thermal stresses upon cooling to room
temperature. Apparent shear strength was determined by a single-lap ap-
b) Direct soldering was performed using the SnAgTi(Ce, Ga) parent shear test sketched in Fig. 3a. Samples were prepared from
solder alloy. Soldering was made with the ultrasonic soldering 6 6 2 Al2O3 ceramic plates joined on 12 12 13 mm alumi-
system (USS-9510, MBR Electronics, Switzerland) using a 6 mm num blocks. The test was performed with a Zwick Z005 (Zwick,
diameter tip. Such joining was successfuly used in our recent re- Germany), universal testing machine with a constant deformation
search on joining ceramic to aluminum alloy [17]. Cleaned samples rate of 0.5 mm/min and with the recording of the applied force.
(10 min in acetone lled ultrasound bath) were heated to 260 C Apparent shear strength was simply calculated as a maximum
and solder alloy was melted on both surfaces, ceramic and alu- force divided by the joint surface area.
minum. The wetting of the solder was promoted with the sol- Tribological characterization was carried out with the pin on
dering tip with 15 W of ultrasound power at 40 kHz. The tem- disc laboratory scale testing apparatus at Centro Ricerche Fiat
perature of the tip was 260 C and the time of ultrasonic assisted (CRF), Italy as shown in Fig. 3b. The applied force was 200 N and
wetting was 15 s. Both parts were then joined together, positioned the rotational speed of sample was 850 rpm. Total time of the test
and cooled down in air to ambient temperature. Since the sol- lasted 900 s. Air cooling system was used to simulate car brakes
dering is done at a relatively low temperature the thermal stresses during running vehicle. The temperature on the sample surface
are smaller than in the case of brazing. However, the thermal was measured with a pyrometer. Two different counterpart pad
Fig. 3. Sketch of an apparent shear test (a) and tribological test (b).
15742 L. Gorjan et al. / Ceramics International 42 (2016) 1573915746
materials were used for the tests; a) a reference pad material ty-
pical for cast iron disc brakes supplied by CRF and b) a harder type
of pad material supplied by Edertek.
Fig. 6. Low magnication cross section micrograph of Al2O3 joint to aluminum alloy in a two-step vacuum process using CuSnTiZr braze alloy is shown in g. a). Elements
were identied by EDX analysis. Figure b) shows a magnied interface area between ceramic and ller metal.
Fig. 7. A shear fracture surfaces on the aluminum side (a) and on the ceramic side (b). A rough metallic surface left over was found on both sides. The residual metal is also
clearly seen from the side view of ceramic part (c).
solder/aluminum interface. Tin/titanium intermetallic grains were detachment of ller alloy from the ceramic surface. Typical shear
found through the braze layer. fracture surfaces are shown in Fig. 9. Large areas of exposed
Single-lap apparent shear strength was measured on samples ceramic were found; a consequence of the adhesion failure during
with 6 6 2 mm3 Al2O3 plates soldered on a 12 12 13 mm3 the shear test. In other areas residual solder alloy was found on the
aluminum alloy block. Two mechanisms of fracture were ob- ceramic surface. It was conrmed by EDX analysis that the residual
served: a) the cohesive failure of the ller alloy and b) the metal is solder alloy and not aluminum alloy which is in
15744 L. Gorjan et al. / Ceramics International 42 (2016) 1573915746
Fig. 9. Fracture surfaces on the aluminum side (a) and on the ceramic side (b). Mixed failure mechanism was observed. Cohesive failure of solder layer and detachment of
solder from ceramic surface.
L. Gorjan et al. / Ceramics International 42 (2016) 1573915746 15745
Fig. 10. Apparent shear strengths of 6 mm 6 mm Al2O3 samples soldered by Sn-Ag-Ti solder alloy or brazed by Cu-Sn-Ti-Zr alloy are presented in a). Bars present average
value and vertical line present standard deviation. Typical stress-strain curves are shown in b). Black lines are for Sn-Ag-Ti soldered samples and grey-dashed lines are for
Cu-Sn-Ti-Zr brazed samples.
major challenges. Two different approaches for joining were ca. 6 6 mm2) part to aluminum, the ceramic is cracked during
investigated. the joining process.
Although the two steps vacuum brazing with Diabraze Cu-Sn- Using the lower melting point Sn-Ag-Ti active solder a crack
Ti-Zr braze forms a good bonding to the ceramic surface, the free bonding can be achieved for ceramic plates with size of
thermal stresses are so large that when brazing a large ceramic (4 20 mm 20 mm. Larger areas can be covered by multiple plates;
Fig. 11. Photograph of cracked disc after soldering made from one ceramic piece (a) and crack-free disc with segmented ceramic cover soldered on aluminum alloy substrate
(b). The disc after the tribological test is show on photo c) with clearly visible tribo-layer deposited from the friction with the pad. The detail of tribolayer at the edge between
two ceramic plates is shown in gure g).
15746 L. Gorjan et al. / Ceramics International 42 (2016) 1573915746
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