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<p>Carbon-Carbon (C<sub>f</sub>-C) composites are widely used in aerospace and nuclear applications due to their low density, excellent thermal stability, and superior mechanical properties. However, joining C<sub>f</sub>-C to metals, ceramics, or itself remains challenging due to poor wettability and a large coefficient of thermal expansion (CTE) mismatch, leading to residual stresses, interfacial reactions, and joint degradation. Brazing has emerged as a promising solution with the use of active filler alloys. This review compares different filler systems based on wettability and performance. Al, Ag, and Cu-based fillers provide moderate joint strength (~ 20–50&#xa0;MPa) but are suitable for lower-temperature applications. In contrast, Ni and Ti-based fillers provide higher strength (~ 50–70&#xa0;MPa) and improved thermal performance (up to ~ 900&#xa0;°C), although residual stresses and interfacial brittleness remain key challenges. In addition, recent approaches, such as particle-reinforced fillers and interlayer coatings, have shown potential in reducing residual stresses and improving joint reliability. This review highlights the relationships between filler composition, microstructure, wettability, and mechanical performance, and outlines current limitations and future directions for developing advanced brazing fillers for C<sub>f</sub>-C composite joining.</p> Graphical Abstract <p></p>

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Comprehensive review: challenges, strategies, and prospects of brazing fillers for joining carbon-carbon composites with self and other materials

  • 期刊论文

  • 发表日期：

    2026年5月12日

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  • V. Vignesh,
  • Sudheer Reddy Beyanagari,
  • R. Vaira Vignesh,
  • M. Govindaraju

摘要

Carbon-Carbon (Cf-C) composites are widely used in aerospace and nuclear applications due to their low density, excellent thermal stability, and superior mechanical properties. However, joining Cf-C to metals, ceramics, or itself remains challenging due to poor wettability and a large coefficient of thermal expansion (CTE) mismatch, leading to residual stresses, interfacial reactions, and joint degradation. Brazing has emerged as a promising solution with the use of active filler alloys. This review compares different filler systems based on wettability and performance. Al, Ag, and Cu-based fillers provide moderate joint strength (~ 20–50 MPa) but are suitable for lower-temperature applications. In contrast, Ni and Ti-based fillers provide higher strength (~ 50–70 MPa) and improved thermal performance (up to ~ 900 °C), although residual stresses and interfacial brittleness remain key challenges. In addition, recent approaches, such as particle-reinforced fillers and interlayer coatings, have shown potential in reducing residual stresses and improving joint reliability. This review highlights the relationships between filler composition, microstructure, wettability, and mechanical performance, and outlines current limitations and future directions for developing advanced brazing fillers for Cf-C composite joining.

Graphical Abstract