Towards efficient heat transfer at heterogeneous interfaces through seamless interfacial reaction strategy

Heat-resistant equipment faces thermal failure and catastrophic structural failures due to heat build-up. Effective thermal evacuation design between enhanced heat sources and high thermal conductivity materials is critical for thermal control techniques. The main problem constraining heat evacuation is the difficulty of conventional thermal interface materials to adequately achieve effective contact between the two. We propose a seamless interfacial reaction strategy using melted liquid braze to achieve 100 % metallurgical bonding at the interface. This approach eliminates interfacial gaps and enables orderly, stable thermal evacuation through the heat source-brazing seam-heat sink pathway. The joint with thermal conductivity obtained by this interfacial reaction strategy shows a thermal conductivity of 31.2–35.5 W·m⁻¹·K⁻¹ (600–900 °C), which is 600 % higher than conventional mechanical joints. And the shear strength of the C_f/C-Haynes 230 joint reaches 21 MPa at room temperature, exceeding that of the majority of carbon-metal joints. The joint maintains excellent stability under 10 heat cycle impacts throughout the service temperature range, ensuring its adaptability for long-term use in extreme environments.