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Zr-Cu filler metal is proposed for SiC ceramic under special working conditions, as a novel type of the active filler metal, the difference of physical and chemical properties between SiC ceramic and Zr-Cu filler metal leads to greater residual stress in the joint, which affects the mechanical properties of brazing SiC ceramic joint. Based on the finite element method (FEM) simulation, the residual stress of the joint is simulated to guide the design of Zr-based filler metal and formulation of brazing process. The residual stress distribution of SiC ceramic joints brazed at 1200 °C with different thickness of the filler metal and cooling rate is simulated by ANSYS software. The simulation results of the residual stress are verified by brazing experiments and XRD measurements. The results show that the simulated residual stress of the joint is mainly axial compressive stress. The axial compressive stresses are the lowest when the filler metal thickness is 0.1 mm and the cooling rate is 2 °C /min, and increase with the increase of the filler metal layer thickness and cooling rate. The shear strength of the brazed SiC ceramic joint that achieves the highest with 2 °C /min is about 72 MPa, and then decreases with the increase of cooling rate. The experimental test of residual stress in different locations of the brazed SiC ceramic joint basically coincide with the FEM simulation.

FEM Simulation and Verification of Brazing SiC Ceramic with Novel Zr-Cu Filler Metal