Feasibility study on electrically conductive joining of MoSi2 electrodes for spark plugs

Despite the often outstanding functional as well as (high temperature-) mechanical properties of ceramics, their usage is often limited due to their inherent brittleness. This also compromises the joining with metals, which is often indispensable for engineering applications. In this context, electrically conductive ceramics like MoSi ₂ are promising materials for the application as electrodes where high temperatures in harsh environments are present (e.g., in spark plugs for large gas engines). Due to the difficult joining of the respective materials, long-term experiments are thereby often still pending. In this work, adhesive bonding, brazing, tungsten inert gas-, and resistance welding were performed to evaluate their applicability for generating electrically conductive as well as mechanically reliable joints between MoSi ₂ and Inconel 600, aiming to utilize MoSi ₂ electrodes in spark plugs. Fractographic analyses are performed to understand cracks associated with the high (thermo-) mechanical stresses. Additionally, a finite element model was set up for a deeper understanding of the observed fracture behavior. While adhesive bonding is acceptable for short-term experiments at low temperatures, brazing and resistance welding may qualify for fast and reliable manufacturing of spark plugs with ceramic electrodes.