Comprehensive review: challenges, strategies, and prospects of brazing fillers for joining carbon-carbon composites with self and other materials

IF 6.2 3区材料科学 Q2 CHEMISTRY, MULTIDISCIPLINARY

Carbon Letters Pub Date : 2026-05-12 DOI:10.1007/s42823-026-01076-9

V. Vignesh, Sudheer Reddy Beyanagari, R. Vaira Vignesh, M. Govindaraju

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Abstract

Carbon-Carbon (C_f-C) composites are widely used in aerospace and nuclear applications due to their low density, excellent thermal stability, and superior mechanical properties. However, joining C_f-C to metals, ceramics, or itself remains challenging due to poor wettability and a large coefficient of thermal expansion (CTE) mismatch, leading to residual stresses, interfacial reactions, and joint degradation. Brazing has emerged as a promising solution with the use of active filler alloys. This review compares different filler systems based on wettability and performance. Al, Ag, and Cu-based fillers provide moderate joint strength (~ 20–50 MPa) but are suitable for lower-temperature applications. In contrast, Ni and Ti-based fillers provide higher strength (~ 50–70 MPa) and improved thermal performance (up to ~ 900 °C), although residual stresses and interfacial brittleness remain key challenges. In addition, recent approaches, such as particle-reinforced fillers and interlayer coatings, have shown potential in reducing residual stresses and improving joint reliability. This review highlights the relationships between filler composition, microstructure, wettability, and mechanical performance, and outlines current limitations and future directions for developing advanced brazing fillers for C_f-C composite joining.

Graphical Abstract

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综合综述：碳-碳复合材料与自材料和其他材料钎焊填料的挑战、策略和前景

碳-碳（Cf-C）复合材料由于其低密度、优异的热稳定性和优异的机械性能而广泛应用于航空航天和核应用。然而，由于较差的润湿性和较大的热膨胀系数（CTE）失配，将Cf-C与金属、陶瓷或其本身结合仍然具有挑战性，从而导致残余应力、界面反应和接头降解。随着活性填充合金的使用，钎焊已成为一种很有前途的解决方案。这篇综述比较了不同的填料系统的润湿性和性能。铝、银和铜基填料提供中等强度的接头（~ 20 - 50mpa），但适用于低温应用。相比之下，Ni和ti基填料具有更高的强度（~ 50-70 MPa）和更好的热性能（高达~ 900°C），尽管残余应力和界面脆性仍然是主要挑战。此外，最近的方法，如颗粒增强填料和层间涂层，已经显示出减少残余应力和提高接缝可靠性的潜力。本文重点介绍了填料成分、微观结构、润湿性和机械性能之间的关系，并概述了目前开发用于Cf-C复合材料连接的先进钎焊填料的局限性和未来发展方向。图形抽象

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来源期刊

Carbon Letters CHEMISTRY, MULTIDISCIPLINARY-MATERIALS SCIENCE, MULTIDISCIPLINARY

CiteScore

7.30

自引率

20.00%

发文量

118

期刊介绍： Carbon Letters aims to be a comprehensive journal with complete coverage of carbon materials and carbon-rich molecules. These materials range from, but are not limited to, diamond and graphite through chars, semicokes, mesophase substances, carbon fibers, carbon nanotubes, graphenes, carbon blacks, activated carbons, pyrolytic carbons, glass-like carbons, etc. Papers on the secondary production of new carbon and composite materials from the above mentioned various carbons are within the scope of the journal. Papers on organic substances, including coals, will be considered only if the research has close relation to the resulting carbon materials. Carbon Letters also seeks to keep abreast of new developments in their specialist fields and to unite in finding alternative energy solutions to current issues such as the greenhouse effect and the depletion of the ozone layer. The renewable energy basics, energy storage and conversion, solar energy, wind energy, water energy, nuclear energy, biomass energy, hydrogen production technology, and other clean energy technologies are also within the scope of the journal. Carbon Letters invites original reports of fundamental research in all branches of the theory and practice of carbon science and technology.