DIRECT CERAMIC-METAL JOINING: STRONG BONDS
Victor A. Greenhut
1st CORNING/SAINT-GOBAIN  MALCOLM G. MCLAREN DISTINGUISHED CHAIR IN CERAMIC ENGINEERING
CERAMIC & MATERIALS ENGINEERING
RUTGERS UNIVERSITY
607 TAYLOR ROAD
PISCATAWAY, N J 08854–8065 USA
 + 732.445.3870
 + 732.445.5584
 greenhut@alumina.
rutgers.edu
The Ceramic-Metal Systems Group at Rutgers University has investigated direct ceramic–metal joining,
often termed the “Gas-Metal Eutectic Method”, “Direct Bond Copper” (DBC) or “Plate and Bond” for over
two decades. This activity has resulted in strong, long-lasting bonds both between various ceramics and
metals, and between students, collaborators and myself.
A brief history of the Group’s R&D efforts will develop a picture of progress made in our understanding and
effective application of this rapidly growing technology. The research path will trace important
contributions and continuing interactions with my dissertation students, undergraduates, high school
students, industry and faculty colleagues. Included will be: effective techniques for the control of bond
quality, eliminating trace contamination defects, bond strength variation with ceramic composition, bonding
to non-oxide ceramics, thermal exposure and thermal shock failure…Many of the concepts are adaptable
to other ceramic-metal bonds and metallization. Interactions with various companies and consortia have
lead to useful application of what we learned. Technology transfer continues on an international basis. The
presentation will culminate with a potentially important new bonding technology - the “Transient Eutectic
Phase Process* (TEPP*), our new method for joining, developed as an extension of our direct bonding
program. The TEPP invention is a fundamental technology with general applicability. TEPP produces
strong interfacial bonds with great process flexibility, excellent elevated temperature stability, reduced
thermo-elastic stress and other practical benefits. Several companies here and abroad are beginning to
apply TEPP to demanding applications.
* Patent Pending
Victor Greenhut authored/co-authored over 170 publications on materials, edited three
books and wrote several monographs on ceramic-metal joining, composites and metals.
Currently, he is authoring a book on SEM. Dr. Greenhut received the 2002 Mueller Award in
Advanced Engineered Ceramics. He received 1st (twice) and 2nd prizes from the Engineering
Ceramics Division of the American Ceramic Society (AcerS) for research and development of
ceramic fiber-ceramic matrix composites and of direct metal bonding to non-oxide and oxide
ceramics (International Conference and Exposition on Advanced Ceramics and Composites). He
received the Teetor Award (SAE) for research activities (senior category) and the Army Science
Conference Award (2nd Prize) for research development of hypervelocity impact resistant alloys.
He was awarded 1st (four times), 2nd (twice) and 3rd prizes in the International Ceramographic
Exhibition of the American Ceramic Society.
Dr. Greenhut is a Fellow of the American Ceramic Society (ACerS) and a member of its
Panel of Fellows. He was 2002-03 President of the National Institute of Ceramic Engineers
(NICE). He was on the Board of Directors of ACerS from 1998-2000 and was Trustee,
Counselor and Chair of the Engineering Ceramics Division. He is an ABET engineering program
accreditor for NICE and TMS. He was an European Union (EU) Advisor for Science and
Technology, and former President of the Ceramic Association of New Jersey. Prof. Greenhut is
a Distinguished Visiting Scientist at the National Institute of Standards and Technology.
Victor Greenhut is a founding Master Teacher for the Graduate School at Rutgers
University. A founding Distinguished Mentor of ACerS, he also mentors disadvantaged/minority
NJ high school students for Project SEED (ACS). As dissertation director, he has successfully
advised 17 Ph.D.’s and 15 M.S.’s to degree and has been major advisor to 14 successful
Ph.D.’s in other disciplines. He currently teaches undergraduate and advanced Ceramic-Metal
Systems, Scanning Electron Microscopy and X-Ray Microanalysis lecture/lab, X-Ray and
Spectroscopic Methods lecture/lab, and Introduction to Ceramics. He directed and instructed
international short courses to over 3,700 engineers/professionals in ceramics, metals, ceramicmetal systems, fractography …