A novel method for strengthening C/C composite joint with high entropy alloy/Ni composite interlayers by spark plasma sintering: In-situ synthesis of high entropy cermet joint structure

C/C composite was successfully brazed with TiZrHfTa/Ni or ZrHfNbTa/Ni composite interlayers using spark plasma sintering. The influence of different interlayers and joining parameters on the joint morphology, shear strength at room temperature and 1000 °C was investigated. For both composite interlayers, the C/C joints obtained at 1800 °C for 30 min consisted of a single high entropy cermet structure, with a near equimolar high entropy carbide hard phase and a near pure Ni binder phase. However, the use of different composite interlayers resulted in differences in the elastic modulus and hardness of the formed high entropy carbide phase. The maximum shear strengths of the obtained C/C composite joints using TiZrHfTa/Ni and ZrHfNbTa/Ni interlayers at room temperature were close, with value of 37.49 ± 1.44 MPa and 38.95 ± 1.26 MPa, respectively. Because (Zr-Hf-Nb-Ta)C had better high-temperature stability than (Ti-Zr-Hf-Ta)C, the obtained C/C-ZrHfNbTa/Ni-C/C joint exhibited a higher shear strength of 28.54 ± 1.71 MPa at 1000 °C. After shear testing at both room temperature and 1000 °C, fractures in all joints predominantly occurred within the C/C composite near the reaction layer, indicating a substrate failure mode. The use of composite interlayers resulted in C/C composite joints with excellent shear strength, primarily due to the in-situ synthesized high entropy cermet reaction layer, which provided superior strength and toughness. Additionally, the laser-textured pattern on the C/C composite surface formed numerous interlocking structures at the joint interface, further enhancing the joints' shear strength.