Joining of ceramic materials using spin-on interlayer

Using various spin-on materials with submicron initial coating thickness, oxide ceramics including alumina, partially stabilized zirconia, fully stabilized zirconia, alumina-zirconia composites, hydroxyapatite, and MaCor(TM) and non-oxide ceramics including silicon carbide and magnesium fluoride have been joined using either microwave heating or conventional heating with applied low external pressure for a range of 40 minutes to 60 minutes. Non-oxide ceramics including MgF2 and SiC were joined at a low temperature (700°C and 900°C) using ceramic precusor spin-on interlays transformed into an amorphous ceramic upon heating. SEM micrographs showed smooth bond layers with thickness ranging from ∼0 to 10 microns.;Prior to joining, notches about 400 microns in depth and 350 microns in width were cut into selected specimens using a low speed diamond saw for alumina-zirconia composites, partially stabilized zirconia, fully stabilized zirconia, hydroxyapatite, and MaCor(TM). Microscopic investigation of the joined specimens showed that the notch dimensions had changed by less than 3% on average.