Reactive metallic microparticles for thermal joining applications

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Reactive systems consisting of aluminium (Al) and nickel (Ni) have the unique ability to generate reaction temperatures of up to 1500 °C for a few milliseconds when exposed to an external energy source. This thermal reaction energy can be used to join via welding, bonding, or adhesion. These systems are commercially available only in the form of nanofoils. There are several disadvantageous characteristics of the nanofoils for joining processes, including the brittle nature of the material and the limitation of applications to planar geometries. To address these restrictions, the objective of this research project is to develop and characterize a new, more flexible format of applying the beneficial reaction properties of Al-Ni systems in joining applications, namely microparticles. To facilitate joining via Al-Ni particles in production engineering, a holistic approach is pursued. Detailed investigations on wet-chemical and mechanical synthesis of reactive microparticles provide the basis. In order to attain profound process understanding for thermal joining applications, reactive microparticles are characterized regarding their properties prior to, during, and after the activation of the reaction via microwave energy. The identified effects and interdependencies allow to draw conclusions about the two distinct synthesis routes and form the basis for the modelling of process behaviour.