Next Article in Journal
Study on the Strength Characteristics of Ion-Adsorbed Rare Earth Ore Under Chemical Leaching and the Duncan–Chang Model Parameters
Previous Article in Journal
Surface Characterization of Hot-Rolled AISI 440C Round Wire at the Different Steps of the Typical Production Process
Previous Article in Special Issue
Dynamic Compression and Blast Failure Behavior of a Biomimetic Novel Lattice with Vertex Modifications Made of 316L Stainless Steel
 
 
Font Type:
Arial Georgia Verdana
Font Size:
Aa Aa Aa
Line Spacing:
Column Width:
Background:
This is an early access version, the complete PDF, HTML, and XML versions will be available soon.
Article

Predictive Modeling of Shear Strength for Lotus-Type Porous Copper Bonded to Alumina

1
Department of Materials Science and Engineering, Inha University, Incheon 22212, Republic of Korea
2
R&D Center, Lotus Materials Co., Ltd., Incheon 22212, Republic of Korea
3
Department of Manufacturing Innovation School, Inha University, Incheon 21999, Republic of Korea
4
Department of Electronic Materials Engineering, Hoseo University, Asan 31499, Republic of Korea
*
Authors to whom correspondence should be addressed.
Metals 2025, 15(10), 1103; https://doi.org/10.3390/met15101103
Submission received: 3 September 2025 / Revised: 26 September 2025 / Accepted: 28 September 2025 / Published: 3 October 2025
(This article belongs to the Special Issue Fracture Mechanics of Metallic Materials—the State of the Art)

Abstract

This study investigates the shear strength of lotus-type unidirectional porous copper bonded to alumina substrates using the Direct Bonded Copper (DBC) process. Porous copper specimens with various porosities (38.7–50.9%) and pore sizes (150–800 μm) were fabricated and joined to alumina discs. Shear testing revealed that both porosity and pore size significantly affect the interfacial strength. While higher porosity led to reduced shear strength, larger pore sizes enhanced the maximum shear strength owing to increased local contact areas and crack coalescence in the alumina substrate. Fractographic analysis using optical microscopy and SEM-EDS confirmed that failure mainly occurred in the alumina, with local fracture associated with pore distribution and size. To improve strength prediction, a modified model was proposed, reducing the error from 12.3% to 7.5% and increasing the coefficient of determination (R²) from 0.43 to 0.74. These findings highlight the necessity of considering both porosity and pore size when predicting the shear strength of porous copper/alumina DBC joints, and they provide important insights for optimizing metal structures in metal–ceramic bonding for high-performance applications.
Keywords: direct bonded copper (DBC); lotus-type porous copper; shear strength; pore diameter; metal–ceramic bonding direct bonded copper (DBC); lotus-type porous copper; shear strength; pore diameter; metal–ceramic bonding

Share and Cite

MDPI and ACS Style

Choi, S.-G.; Kim, S.; Lee, J.; Kim, K.-S.; Hyun, S. Predictive Modeling of Shear Strength for Lotus-Type Porous Copper Bonded to Alumina. Metals 2025, 15, 1103. https://doi.org/10.3390/met15101103

AMA Style

Choi S-G, Kim S, Lee J, Kim K-S, Hyun S. Predictive Modeling of Shear Strength for Lotus-Type Porous Copper Bonded to Alumina. Metals. 2025; 15(10):1103. https://doi.org/10.3390/met15101103

Chicago/Turabian Style

Choi, Sang-Gyu, Sangwook Kim, Jinkwan Lee, Keun-Soo Kim, and Soongkeun Hyun. 2025. "Predictive Modeling of Shear Strength for Lotus-Type Porous Copper Bonded to Alumina" Metals 15, no. 10: 1103. https://doi.org/10.3390/met15101103

APA Style

Choi, S.-G., Kim, S., Lee, J., Kim, K.-S., & Hyun, S. (2025). Predictive Modeling of Shear Strength for Lotus-Type Porous Copper Bonded to Alumina. Metals, 15(10), 1103. https://doi.org/10.3390/met15101103

Note that from the first issue of 2016, this journal uses article numbers instead of page numbers. See further details here.

Article Metrics

Back to TopTop