Novel Ceramic to Metal Joint Design Optimization using Finite Element Analysis

Document Type

Student Presentation

Presentation Date



College of Engineering


Materials Science and Engineering

Faculty Sponsor

Brian J. Jaques


Finite element analysis (FEA) was used to optimize the design of a novel ceramic to metal joint that was developed to withstand thermal cycling in high temperature and pressure environments. The current operational target is for the joint to remain hermetic through 10 cycles from atmospheric conditions to a temperature and pressure of 800 °C and 3000 psi respectively. FEA efforts, in conjunction with experimental results, were used to understand the failing mechanisms and minimize the stresses at critical locations of the joint. Two design parameters that were investigated include material selection of the joint components and thickness of the seal design. Resulting FEA optimization suggests that a higher performing material (i.e. Haynes alloy 242, Inconel 617, or 440C steel) is needed for the metal enclosure and that the seal thickness should be increased. The FEA results are guiding experimental efforts and increasing the efficacy of future ceramic to metal joint designs. This dissimilar material joining technology will enable high temperature heat exchangers, which will allow for higher efficiency power generation systems.

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