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

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 presen ts finite element method simulations of the residual stress field in Al2O3- AISI 304 steel joints using interlayers, Different interlayer materials (Ti , Ni, Mo, and Cu) were considered, either separately or in combination. Cal culations show that among the different interlayer materials considered, Cu and Ti/Cu are most effective in reducing the thermal stresses and that thi s role is determined mainly by the ductility of the interlayer material. Th e 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, MST/4511.