Building a nano-crystalline α-alumina layer at a liquid metal/sapphire interface by ultrasound

Transitional layers at the metal/ceramic interface play an very important role in ceramic joining. In this study, sapphire blocks were ultrasonically dipped in liquid Sn-Zn-Al alloy. It is found that the ultrasound promoted rapid oxidation reaction of aluminum at the Sn-Zn-Al/sapphire interface at 230 °C in the ambient atmosphere, resulting in the formation of a nano-crystalline α-Al₂O₃ layer (NCAL). In a ∼2 nm boundary layer of the NCAL, the lattice matches the sapphire substrate well. Thus, a smooth transition of the lattice from sapphire to metal was formed through the NCAL. Ultrasonically soldered sapphire joints were made with Sn-Zn-Al as the filler alloy. Compressive shear strength of the joints reached 43-48 MPa, which is relatively high comparing to other Al₂O₃ joints made of Sn alloys doped with Ti or Rear Earth elements. Thus, a new mechanism of ultrasonic soldering, i.e. building an oxide transitional layer on the surface of the solid, was revealed. We expect this sonochemical process to be applicable to other metal/oxide systems.