Joining ceramics to metals using metallic foam

A general method for brazing ceramics to metals using a compliant metallic foam as a buffer layer has been developed. Using stainless steel foams, bonds between alumina and 316 stainless steel with shear strengths up to 33 MPa have been achieved. The resultant ductility enhances the resistance of the joint to thermal cycling; AlN-Inconel 600 bonds exhibited good thermal shock resistance. Alumina-stainless steel bonds withstood more that 60 thermal cycles between 200 and 800 °C in air.