Experimental and Process Optimization Study on Thermal Stress Reduction in TiC–Steel Brazed Joints Using Polymer-Derived Composite Interlayers

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Year : 2026 | Volume : 14 | 03 | Page :
    By

    Yogesh Agrawal,

  • Sanjay D Nikhade,

  • Yogesh Ramdas Mahulkar,

  • Dhanashri Jayant Ganore,

  • Anil Singh Yadav,

  • Nandkishor Sawai,

  1. Associate Professor, Department of Mechanical Engineering, Sandip Institute of Technology and Research Centre, Nashik, Maharashtra, India
  2. Associate Professor, Department of Mechanical Engineering, Sandip University, Nashik, Maharashtra, India
  3. Assistant Professor, Department of Mechanical Engineering, Manav School of Engineering and Technology, Akola, Maharashtra, India
  4. Assistant Professor, Department of Mechanical Engineering, Sandip University, Nashik, Maharashtra, India
  5. Assistant Professor, Department of Mechanical Engineering, Bakhtiyarpur College of Engineering (Science, Technology and Technical Education Department, Govt. of Bihar), Bakhtiyarpur, Patna, Maharashtra, India
  6. Associate Professor, Department of Mechanical Engineering, Sandip Institute of Technology and Research Centre, Nashik, Maharashtra, India

Abstract

In this, an experimental investigation aimed at reducing crack formation due to thermal stress in TiC-steel brazed joints through optimization of key process parameters is presented. The primary objective was to develop an integrated and reliable brazing strategy by examining the effects of filler material selection, brazing gap, cooling conditions and type of flux. In this study, polymer-derived composite interlayers were developed through controlled synthesis and nanocomposite engineering to mitigate residual stresses. Advanced characterization techniques were employed to correlate molecular structure, interfacial properties, and thermal behavior with stress reduction efficiency. The incorporation of functional and nanostructured fillers improved thermal conductivity, mechanical compliance, and stress redistribution capability. Experimental results demonstrated significant reduction in crack formation and improved joint integrity under thermal cycling conditions. Furthermore, sustainable and bio-based polymer approaches were explored to enhance environmental compatibility without compromising performance. The developed interlayer system exhibited superior thermal fatigue resistance and reliability, highlighting its potential for advanced structural, energy, and high-temperature engineering applications. Earlier methods of using silver-based filler materials and powder flux caused a number of problems, including oxide formation at the joint interface, high thermal stress (up to 85-90%) reduced tensile strength, and poor service performance of TC chisels. The results showed a significant reduction in thermal stress levels by about 10-15%, as well as improved joint integrity and elimination of crack formation. Optimal brazing conditions were identified in the temperature range of 890-920 ° C, with a joint clearance of 0.4-0.6 mm and controlled furnace cooling. The improved performance is attributed to the ability of the Cu-rich filler material to accommodate the thermal diffusion gap between TiC and steel.

Keywords: Brazing, Composite interlayers, Multiscale modelling, Polymer-derived interlayers, Sustainable polymers, Thermal Stress

How to cite this article:
Yogesh Agrawal, Sanjay D Nikhade, Yogesh Ramdas Mahulkar, Dhanashri Jayant Ganore, Anil Singh Yadav, Nandkishor Sawai. Experimental and Process Optimization Study on Thermal Stress Reduction in TiC–Steel Brazed Joints Using Polymer-Derived Composite Interlayers. Journal of Polymer & Composites. 2026; 14(03):-.
How to cite this URL:
Yogesh Agrawal, Sanjay D Nikhade, Yogesh Ramdas Mahulkar, Dhanashri Jayant Ganore, Anil Singh Yadav, Nandkishor Sawai. Experimental and Process Optimization Study on Thermal Stress Reduction in TiC–Steel Brazed Joints Using Polymer-Derived Composite Interlayers. Journal of Polymer & Composites. 2026; 14(03):-. Available from: https://journals.stmjournals.com/jopc/article=2026/view=243380


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Ahead of Print Subscription Original Research
Volume 14
03
Received 23/04/2026
Accepted 06/05/2026
Published 11/05/2026
Publication Time 18 Days
35

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