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A review is presented of the design of suitable materials systems for joining by high-temperature plastic deformation, details of the joining techniques, microstructures and properties of the resulting composite bodies, and prospects and limitation for this type of joining technology. Joining parameters and resulting forms are discussed for Al2O3/mullite particulate composites, Y2O3-stabilized ZrO2 particulate/Al2O3 particulate and whisker-reinforced composites, hydroxyapatite bioceramics, La0.85Sr0.15MnO3 electronic ceramics, MgF2 optical ceramics, and Ni3Al intermetallics. Results are contrasted with those obtained by other methods of joining brittle, high-temperature materials, with special focus on durability and mechanical properties.

A plastic deformation process was demonstrated to self-join 3 mol.% yttria partially stabilized zirconia (3Y-TZP)/hydroxyapatite (HA) composites. The 3Y-TZP/40 vol.% HA composites were fabricated by conventional ceramic processing by cold pressing premixed 3Y-TZP and HA powders into pellets. Densification ( approximately 90%) of composites was achieved by sintering composite powder compacts at 1450 degrees C for 5h. Optimum self-joining of 3Y-TZP/40 vol.% HA composites was obtained at 1300 degrees C for a strain rate of 5 x 10(-5)/s. The flow stress during joining was 40 MPa. Microstructural and mechanical characterizations of the joint interface demonstrated that there were no discernible differences between the joint and the composite material away from the interface.

A plastic deformation process was demonstrated to self-join hydroxyapatite (HA), fabricating pore-free joints at 1275°C at a strain rate of 10−5 s−1. To determine optimum joining conditions, high-temperature compressive deformation of HA was investigated for strain rates between 5 × 10−6 and 10−4 s−1 at temperatures 1175–1275°C. X-ray diffraction revealed primarily the HA phase with the presence of tri- and tetra-calcium phosphate phases. Steady-state flow stresses were 0.6–45 MPa and increased with increasing strain rates. Stress exponents of ≈1 indicated a viscous diffusion-controlled deformation mechanism with an activation energy of ≈354±36 kJ/mol. Absence of cavitation and grain shape changes was consistent with grain boundary sliding.