Durable Joining of Dissimilar Materials


Metal/ceramic joints in SOFCs Thermal barrier coatings Metal/ceramic bonding


Survives rapid thermal cycling Thinner than graded joint Eliminates the need to introduce a third material into the joint High strength over a wide range of joint porosities Unlike graded joints, preserves contrast in material properties at the interface


One barrier to solid oxide fuel cell manufacturing is forming robust joints between materials that don’t chemically bond with each other and/or differ greatly in form or particle size, such as metals and ceramics. Berkeley Lab scientists solve this problem by decorating the surface of the more ductile material with particles of the less ductile material via milling and then sinter-bonding this composite to the less ductile materials and/or another material that will sinter with either of the first two materials.

This technique is especially useful in devices where the utility of the joint is derived from a sharp interface between the two materials or where a third bonding material might be incompatible with system requirements. Joints made using this method have proven more durable during rapid thermal cycling than bonds relying on mechanical interlocking of articles or fibers and are more compact than graded joints.

Type of Offer: Licensing

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