Allen H. Simpson

Combustion joining of refractory materials: Carbon-carbon composites

Refractory materials such as carbon possess properties that make joining them difficult. In this work, bonding of a carbon–carbon composite is achieved by employing self-sustained, oxygen-free, high-temperature combustion reactions. The effects of several parameters, such as the composition of the reaction media, and the values of the applied current and pressure, on the mechanical strength of the joint were investigated. It was found that the C–C composite possesses a high activity with the reactive media layer, the level of electrical current used to initiate the reaction and the applied pressure do not need to be excessive to obtain a strong joint. Some aspects of the joining mechanism are discussed in detail.

Novel apparatus for joining of carbon-carbon composites

A novel apparatus for joining carbon-carbon (C-C) composites is presented. This device was designed and built based on the concept of self-sustained oxygen-free high-temperature reactions. A layer of reactive mixture is contained between two disks of C-C composite that are to be joined. The stack is held in place between two electrodes, which are connected to a dc power supply. dc current is used to uniformly initiate the reaction in the reactive layer. The electrodes are also part of the pneumatic system, which applies a load to the stack. The designed hydraulic system is effective, lending to low cost and simplified, rapid, accurate operation. It provides a very short response time ( approximately 10 ms), which is important for the considered applications. All operational parameters such as initial and final loads, applied current, delay time between ignition and final load application, duration of Joule heating, and safety interlocks are controlled by a programable logic controller system. These features make it an efficient, user-friendly and safe machine to join refractory materials. The entire joining process takes place on the order of seconds, rather than hours as required for solid-state joining methods. The mechanical properties of the obtained joints are higher than those for the C-C composites.