Powder brazing filler metals (PBFMs) feature a number of comparative advantages. Among others, these include a low energy consumption, an accurate dosage, a good brazeability, a short production time, and a high production efficiency. These filler metals have been used in the aerospace, automobile, and electric appliances industries. The PBFMs are especially suitable for diamond tools bonding, which involves complex workpiece shapes and requires accurate dosage. The recent research of PBFMs for diamond tools is reviewed in this paper. The current applications are discussed. The CuSnTi and Ni-Cr-based PBFMs have been the two commonly used monolayer PBFMs. Thus, the bonding mechanism at the interface between both the monolayer PBFMs and a diamond tool are summarized first. The ways to improve the performance of the monolayer PBFMs for diamond tools are analyzed. Next, a research of PBFMs for impregnated diamond tools is reviewed. The technical problems that urgently need solutions are discussed. Finally, the challenges and opportunities involved with the PBFMs for diamond tools research and development are summarized, and corresponding prospects are suggested.

Welding copper (Cu) and aluminum (Al) is highly demanded for lightweight and cost-effective manufacturing. However, it faces significant challenges. First, substantial differences in physical properties may lead to high residual stresses and distortion. Second, brittle intermetallic compounds (IMCs) readily form at the interface, severely compromising the joint’s mechanical properties and electrical conductivity. Third, the native oxide film on Al impedes effective wetting and bonding. Therefore, effective control over the interfacial microstructure of the welded joint is essential. This review provides a critical analysis and comparison of several typical welding techniques, including laser welding (LW), friction stir welding (FSW), ultrasonic welding (UW), brazing and soldering, and welding–brazing. These analyses focus on their process characteristics, joint microstructures, and corresponding formation mechanisms. Furthermore, this review synthesizes key strategies for enhancing joint quality, including process parameter optimization, introduction of functional interlayers, and external assistance, aimed at optimizing joint microstructure and minimizing defects. Based on the analysis, this work provides comparative insights into process selection and microstructure control, and highlights future directions: advancing novel methods such as magnetic pulse welding and transient liquid phase bonding; developing intelligent real-time process control to suppress brittle IMCs and associated defects; promoting sustainable practices and establishing standardized performance evaluation; and systematically investigating long-term reliability to support the industrial application of robust Cu/Al joints.

The mixture powders were designed by adding 0 wt.%~1.0 wt.% CeO₂ into the 2205 duplex stainless steel (DSS) powders. The 2205 DSS cladding layer was prepared on the surface of Q345 steel by plasma arc cladding technology. The effects of different CeO₂ contents on the macro-morphology, microstructure composition, and corrosion resistance of the cladding layer were studied. The action mechanism of CeO₂ in the cladding layer was also discussed. The results showed that the addition of CeO₂ modified the appearance and decreased the defect of the cladding layer. Also, the austenite grains were refined, and the austenite proportion was increased under the action of CeO₂. When the CeO₂ content was 0.5 wt.%, the appearance of the cladding layer was optimum; the austenite proportion in the upper cladding layer and the lower cladding layer reached up to 52.6% and 55.5%, respectively, and the crystal changed from columnar to equiaxed. CeO₂ decomposes into Ce element and O element under the action of the plasma arc, after which Ce element is easily absorbed at the grain boundary to reduce the surface tension and improve the fluidity of the liquid metal so as to modify the appearance of the cladding layer. Meanwhile, Ce element primarily reacts with O, S, Al, and Si elements to form low-melting-point oxygen sulfides and are then removed, which eliminates the defect of the cladding layer. Moreover, the high melting point of CeO₂ acts as heterogeneous nucleation sites during solidification, thus improving the value of nucleation rate/growth rate of the grain and promoting the transformation from ferrite to austenite. According to the electrochemical corrosion testing result, Ce element inhibited the enrichment of Cr element at grain boundaries and promoted the formation of Cr₂O₃, which improved the corrosion resistance of the 2205 DSS cladding layer. It was optimum with the CeO₂ content of 0.5 wt.%.

C276 Hastelloy/Q235 Steel cladding plates were prepared by vacuum-sealed hot rolling (VSHR) with a small hole. The effects of different Ni interlayers on the macro-morphology, microstructure, mechanical properties and corrosion resistance of the cladding plates were systematically investigated. The results indicated that without an interlayer, a large number of Mo-rich white M₆C particles formed near the C276 Hastelloy side, along with the formation of black Cr-Mn oxides at the interface. The addition of the Ni interlayer suppressed the diffusion of the C element from the Q235 Steel toward the C276 Hastelloy, consequently reducing the precipitation of M₆C carbides and Cr-Mn oxides. When the Ni interlayer thickness was 0.5 mm, the M₆C carbides on the Hastelloy side disappeared completely. The incorporation of a Ni interlayer increased the hardness of the C276 Hastelloy side and the interface layer, as well as the shear strength of the cladding plate. This was mainly because the Ni interlayer acted as a barrier to suppress the development of a Mo/Cr-depleted zone adjacent to the C276 Hastelloy and decrease interfacial Cr-Mn oxides, thus enhancing interfacial bonding. Under all three conditions, the cladding plates were bent without cracking. Moreover, the addition of a Ni interlayer also improved the corrosion resistance of the cross-section of the C276 Hastelloy. XPS analysis of the passive film revealed that the corrosion resistance was primarily attributed to the formation of Mo- and Cr-containing oxides on the surface. The corrosion resistance reached the optimal with the Ni interlayer thickness of 0.5 mm, in which Mo and Cr played a crucial role.

Mn-based disordered rock-salt (DRX) cathode materials offer high theoretical capacities and operating voltages, rendering them promising candidates for high-energy-density lithium-ion batteries. However, severe interfacial reactions between Mn-based DRX cathodes and the electrolyte can induce surface degradation and a pronounced increase in interfacial impedance. In this study, a LAGP glass ceramic coating layer was introduced onto the surface of Li_1.2Cr_0.3Ti_0.3Mn_0.3O_1.9F_0.1 (LCTMOF) particles to minimize direct contact between the active material and the electrolyte, thereby enhancing the capacity retention over 50 cycles. It delivered an initial discharge capacity of 278.7 mAh g⁻¹ and retained 227.3 mAh g⁻¹ after 50 cycles. Relative to the pristine uncoated cathode, the LAGP glass ceramic coating material achieved a capacity retention of 81.5% together with improved rate performance, retaining a high specific capacity of 184.5 mAh g⁻¹ at a current density of 500 mA g⁻¹. Surface XPS analysis, together with the electrochemical results, suggests that the LAGP glass ceramic coating mitigates cathode interfacial degradation under the investigated cycling conditions.