Bonding interface characteristic and shear strength of diffusion bonded Ti-17 titanium alloy

The bonding interface characteristic and shear strength of diffusion bonded Ti-17 titanium alloy at different bonding time were investigated. The results show that the average size of voids decreases while the amount of voids decreases after increasing to the maximum value with the increasing bonding time. The irregular void with a scraggly edge tends to an ellipse void with smooth surface and then changes to a tiny void with round shape. The grains across bonding interface occur at bonding time of 60 min. The shear strength of bond increases with increasing bonding time, and the highest shear strength of bond is 887.4 MPa at 60 min. The contribution of plastic deformation on the void closure and the increase of shear strength is significant even though the action time of plastic deformation is short.

Effect of joining temperature on microstructure and properties of diffusion bonded Mg/Al joints

The joining of AZ31B Mg alloy to 6061 Al alloy was investigated at different joining temperatures by vacuum diffusion bonding method. The microstructures of Mg/Al dissimilar joints were studied by means of optical microscopy （OM）, scanning electron microscopy （SEM） and energy dispersive X-ray （EDX）. The results show that the thickness of each layer in the diffusion zone increases with the increase of joining temperature, and the microstructure changes obviously. At joining temperature of 440 °C, the diffusion zone is composed of Mg2Al3 layer and Mg17Al12 layer. At joining temperatures of 460 and 480 °C, the diffusion zone is composed of Mg2Al3 layer, Mg17Al12 layer, eutectic layer of Mg17Al12 and Mg-based solid solution. The width of high-hardness zone in the joint increases with increasing joining temperature, and the micro-hardnesses at different locations in the diffusion zone are significantly different. The joining temperature of 440 °C offers the highest tensile strength of 37 MPa, and the corresponding joint exhibits brittle fracture at the intermetallic compound layer of Mg17Al12.

Tungsten/steel diffusion bonding using Cu/W-Ni/Ni multi-interlayer

Diffusion bonding between tungsten and 0Cr13Al stainless steel using a Cu/90W-10Ni powder mixtures/Ni multi-interlayer was carried out in vacuum at 1150 °C with a pressure of 5 MPa for 60 min. The microstructures, composition distribution and fracture characteristics of the joint were studied by SEM and EDS. Joint properties were evaluated by shear experiments and thermal shock tests. The results showed that the joints comprised tungsten/Cu-Ni sub-layer/W-Ni composites sub-layer/Ni sub-layer/0Cr13Al stainless steel. The W-Ni composites sub-layer with a homogeneous and dense microstructure was formed by solid phase sintering of 90W-10Ni powder mixtures. Sound bonding between tungsten base material and W-Ni composites sub-layer was realized based on transient liquid phase (TLP) diffusion bonding mechanism. Joints fractured at bonding zone of W-Ni composites sub-layer and Ni sub-layer during shear testing, and the average strength was 256 MPa. Thermal shock tests showed that joints could withstood 60 thermal cycles quenching from 700 °C to room temperature.

Microstructures and interfacial quality of diffusion bonded TC21 titanium alloy joints

Diffusion bonding of TC21 titanium alloy was carried out at temperature ranging from 780 ℃ to 980 ℃ for 5-90 min.The interfacial bonding ratio,deformation ratio,microstructures and microhardness of the diffusion bonded joints were investigated.Results show that joints with high bonding quality can be obtained when bonded at 880 ℃ for 15？30 min.The microhardness increases with increasing the bonding temperature,while it has a peak value（HV367） when bonding time is prolonged up to 90 min.Fully equiaxed microstructures,bi-modal microstructures and fully lamellar microstructures were observed when bonded in temperature range of 780-880 ℃,at 930 ℃ or 980 ℃,respectively.The volume fraction of α phase first increases and achieves the maximum when bonded at 880 ℃ for 60 min,and then descended.

Interfacial microstructure and chemical stability during diffusion bonding of single crystal Al_2O_3-fibres with Ni25.8Al9.6Ta8.3Cr matrix

BN coated A1203 fibre-reinforced NiAl-alloy composites were fabricated by hot pressing at 1 200-1 400 ℃, and the interracial microstructure and chemical stability of BN coated Al2O3 fibre-reinforced NiAl-alloy composites were investigated by scanning electron microscopy （SEM） and analytical transmission electron microscopy （TEM）. It was found that the complicated chemical reactions and diffusion processes happened in the interface area between BN-layer and Ni25.8A19.6Ta8.3 during the hot pressing at 1 200-1 400 ℃. A continuous AlN-layer was formed at the interface due to the reaction between NiAl and BN. At the same time, Cr diffused extensively into the BN-layer and reacted with boron to form Cr boride precipitates （CrsB3）. In addition, a few particles of Ta-rich phase were also precipitated in NiAl matrix near the interface.

Effect of annealing temperature on joints of diffusion bonded Mg/Al alloys

To study the effect of annealing temperature on the joints between magnesium and aluminum alloys, and improve the properties of bonding layers, composite plates of magnesium alloy（AZ31 B） and aluminum alloy（6061） were welded using the vacuum diffusion bonding method. The composite specimens were continuously annealed in an electrical furnace under the protection of argon gas. The microstructures were then observed using scanning electron microscopy. X-ray diffractometry was used to investigate the residual stresses in the specimens. The elemental distribution was analyzed with an electron probe micro analyzer. The tensile strength and hardness were also measured. Results show that the diffusion layers become wide as the heat treatment temperature increases, and the residual stress of the specimen is at a minimum and tensile strength is the largest when being annealed at 250 ℃. Therefore, 250 ℃ is the most appropriate annealing temperature.

Influences of diffusion bonding process parameters on bond characteristics of Mg-Cu dissimilar joints

In many circumstances,dissimilar metals have to be bonded together and the resulting joint interfaces must typically sustain mechanical and/or electrical forces without failure,which is not possible by fusion welding processes.The melting points of magnesium(Mg)and copper(Cu)have a significant difference(nearly 400℃)and this may lead to a large difference in the microstructure and joint performance of Mg-Cu joints.However,diffusion bonding can be used to join these alloys without much difficulty.This work analyses the effect of parameters on diffusion layer thickness,hardness and strength of magnesium-copper dissimilar joints.The experiments were conducted using three-factor,five-level,central composite rotatable design matrix.Empirical relationships were developed to predict diffusion layer thickness,hardness and strength using response surface methodology.It is found that bonding temperature has predominant effect on bond characteristics.Joints fabricated at a bonding temperature of 450℃, bonding pressure of 12 MPa and bonding time of 30 min exhibited maximum shear strength and bonding strength of 66 and 81 MPa, respectively.

Development of processing windows for diffusion bonding of Ti-6Al-4V titanium alloy and 304 stainless steel with silver as intermediate layer

As titanium alloy is chemically reactive,it is very difficult to join by conventional welding techniques.Titanium alloys can easily pick up nitrogen and oxygen from the atmosphere.In the fusion welding method,brittle intermetallic compounds are formed when joining titanium alloy and stainless steel,which decrease the mechanical behavior of the couples.Hence,for joining of titanium alloy,diffusion bonding is recommended.This work dealt with the measurement of feasible process parameters for diffusion bonding of Ti-6Al-4V and AISI 304 stainless steel with silver as an intermediate layer.The quality of the bonds was confirmed by the lap shear test and microstructural analysis.With the experimental results obtained,diffusion bonding windows were constructed and this will act as reference maps to identify the process parameters for obtaining defect free bond.Bonding was successful in the temperature range of 750-800 °C.Maximum lap shear strength was achieved under a bonding pressure of 5 MPa and holding time of 90 min.

Diffusion bonding of Al 7075 and Mg AZ31 alloys:Process parameters, microstructural analysis and mechanical properties

Al 7075 and Mg AZ31 alloys were joined by diffusion bonding method. Joining process was performed in pressure range of 10-35 MPa at temperatures of 430-450 ℃ for 60 min under a vacuum of 13.3 MPa. The microstructure evaluation, phase analysis and distribution of elements at the interface were done using scanning electron microscopy （SEM）, energy-dispersive X-ray spectroscopy （EDS） and X-ray diffraction （XRD）. The pressure of 25 MPa was determined as the optimum pressure in which the minimum amount of plastic deformation takes place at the joint. Different reaction layers containing intermetallic compounds, such as Al12Mg17, Al3Mg2 andα（Al） solid solution, were observed, in interfacial transition zone （ITZ）. Thickness of layers was increased with increasing the operating temperature. According to the results, diffusion of aluminum atoms into magnesium alloy was more and the interface movement towards the Al alloy was observed. The maximum bond strength of 38 MPa was achieved at the temperature of 440 ℃ and pressure of 25 MPa. Fractography studies indicated that the brittle fracture originated from Al3Mg2 phase.

SUPERPLASTICITY AND DIFFUSION BONDING OF IN718 SUPERALLOY

The superplasticity and diffusion bonding of IN718 superalloy were studied in this article. The strain rate sensitivity index m was obtained at different temperatures and various initial strain rates using the tensile speed mutation method; m reached its maximum value 0.53 at an initial strain rate of 1×10^-4s^-1 at 1253K. The diffusion bonding parameters, including the bonding temperature T, pressure p, and time t, affected the mechanism of joints. When the bonded specimen with 25μm thick nickel foil interlayer was tensile at room temperature, the shear fracture of the joints with nickel foil interlayer took place at the IN718 part. Microstructure study was carried out with the bonded samples. The microstructure shows an excellent bonding at the interfaces. The optimum parameters for the diffusion bonding are： T = 1273-1323K, p = 20-30MPa, t = 45-60min.

Microstructural characterization of the Al/Cu/steel diffusion bonded joint

A vacuum hot-pressed diffusion method was used to prepare an Al/Cu/steel composite with a gradient structure. The Al/Cu interface was investigated layer by layer by means of scanning electron microscopy, energy dispersive X-ray spectrometry, electron probe microanalysis, and Vickers microhardness. The results show that two kinds of intermetallic compounds, Cu9Al4 adjacent to the Cu side and CuAl2 adjacent to the Al side, are formed in the interface of Al/Cu. The conductivity is 0.369 mS/cm in the intermetallic compound with a thickness of 3.5 μm, higher than that of the intermetallic compound with a thickness of 23 μm, in which the conductivity is 0.242 mS/cm.

Vacuum diffusion bonding of Ti_(2)AlNb alloy and TC4 alloy

The Ti_(2)AlNb alloy was joined with TC4 alloy by vacuum diffusion bonding.The relationship between bonding parameters,and joint microstructure and shear strength was investigated.The results indicated that the diffusion of Al,Ti,Nb and V elements across bonding interface led to the formation of three reaction layers:B2/βlayer andα2 layer on the TC4 side,andα2+B2/βlayer on the Ti_(2)AlNb side.The bonding temperature determined the atomic activity,thus controlling the growth of reaction layers and influencing the shear strength of the joint.When the Ti_(2)AlNb alloy and TC4 alloy were bonded at 950℃for 30 min under 10 MPa,the shear strength of the joint reached the maximum of 467 MPa.The analysis on the fracture morphology showed that the fracture occurred within the B2/βlayer and the fracture model was ductile rupture.Meanwhile,the formation mechanism of the Ti_(2)AlNb/TC4 joint was discussed in depth.

Microstructure and mechanical properties of Ti−6Al−4V/Ti−22Al−25Nb joint formed by diffusion bonding

Ti-6Al-4V(wt.%) and Ti-22Al-25Nb(at.%) were joined by diffusion bonding at 950 ℃ and 15 MPa for 100 min, and the microstructure and mechanical properties of the resulting joints were investigated. The composition of the diffusion layer is B2/discontinuous α/α2 layer/necklace-shaped β+α’ layer, where the content of any element at a given point mainly depends on the distance of the point from the interface and the phase type at the point. The tensile strength of the joint is 894 MPa, which is almost the same as that of the Ti-22Al-25Nb base alloy. The fracture surfaces on both sides of the joint are composed of two main regions. One region displays a relatively flat surface and fractures along the bonding interface. The other is composed of a moderate number of irregularly-shaped cavities on the Ti-6Al-4V side and many irregularly-shaped bulges on the Ti-22Al-25Nb side. Both regions result from fracture along the boundaries between β+α’ layers and αp grains or from the transcrystalline fracture of αp grains.

Diffusion Bonding of Ti_3Al Base Alloy

: The effects of diffusion bonding temperature and holding time on the joint strength of Ti3Al base alloy has been investigated in this paper. The shear strength of Ti-14Al-21Nb-3Mo-V alloy diffusion bonding joint under pressure of 12 MPa at 990℃ for 70 min was obtained to 797.6 MPa which approaches the base material strength. In addition, a short-time diffosion bonding process was studied in order to decrease the bonding cost. With the deformation of the specimens of 2.5% and the bonding temperature of 990℃ for 15 min, the bonding strength could reach 801 MPa.

Diffusion Bonding of Silicon Carbide Particulate Reinforced 2024 Al Composites

A study has been made on diffusion bonding of SiCp/2024Ai composites by means of pure Al interlayer. In the condition of TB=843 K, PB=16 MPa, tB= 60 min, the diffusion bonded joint, with a shear strength of 235 MPa, was obtained when a 15 μm thick interlayer was used. The results of the shear testing and SEM indicate that fracture of the joint presented characteristics of ductile rupture.

Microstructures and properties of transient liquid phase diffusion bonded joints of Ni_3Al-base superalloy

An investigation of transient liquid phase (TLP) diffusion bonding of a Ni 3Al base directionally solidified superalloy, IC6 alloy, was presented. The interlayer alloy employed was Ni Mo Cr B powder alloy. The results show that the microstructure of the TLP diffusion bonded joints is a combination of γ solid solution (or a γ+γ′ structure) and borides. With the bonding time increasing, the quantity of the borides both in bonding seam and adjacent zones is gradually reduced, and the joint stress rupture property is improved. The obtained stress rupture property of the TLP bonded joints is on a level with the transverse property of IC6 base materials. [

Interfacial Microstructure of Diffusion Bonded Inconel 738 and Ferritic Stainless Steel Couple

In this study, Inconel 738 alloy was diffusion bonded to a ferritic stainless steel. The effect of bonding temperature on the microstructural development across the joint region was investigated. Following the diffusion bonding, conventional characterization techniques such as scanning electron microscopy （SEM）, energy dispersive X-ray （EDX） and microhardness were used to examine the interracial microstructure. It was seen that bonding temperature was effective on the diffusion of Ni from Inconel 738 to ferritic stainless steel that affected the microstructure of the interface. Austenite phase was formed at the interface as a result of Ni diffusion from the Inconel 738 to the interface.

Diffusion bonding of Ti-6Al-4V to ZQSn10-10 in vacuum

The experimental investigation of the direct diffusion bonding of Ti-6Al-4V to ZQSn10-10 was carried out in vacuum. The microstructure of bonded joint was studied by scanning electron microscopy （SEM）, energy dispersive spectroscopy （ EDS ） and the mechanical properties were detected by the tensile experiments. The microstructure and tensile strength of the joint mainly depend on the bonding temperature and bonding time. A satisfying diffusion bonded interface with a tensile strength of 73.9 MPa can be obtained under the condition of bonding temperature 850℃ for 30 rain. Three kinds of reaction products were observed in the bonded interface, namely β-Ti, CoaTi and CuSn3Ti5. And the brittle Cu3Ti and CuSn3 Ti5 are mainly responsible for lowering the strength of the bonded joint. The diffusion distances of Sn , Cu and Ti and square root of bonding time are approximately linear relationship. And diffusion velocity of Sn, Cu and Ti in the diffusion reaction layer are 0. 013 9,0. 069 7 and 0. 056 4 mm^2/s.

Diffusion bonded transition joint of TC4 to QAl10-3-1.5

Solid-state diffusion bonding has been done to produce transition joint between TC4 and QAl10-3-1.5 at the temperature 850℃ for 60 min. The produced diffusion bonded couples were evaluated by scanning electron microscopy （SEM）, energy dispersive spectroscopy （EDS） and X-ray diffraction （XRD）. SEM revealed the presences of the different reaction regions in the diffusion zone and “kirkendall voids” were observed in the interface. This study indicated the existences of Cu3 Ti, Cu and Ti phases in the diffusion zone of the joint confirmed by XRD. The microhardness tests revealed that the microhardness of TC4 jointing affected zone （ JAZ） is higher than the TC4 base materials, and transition zone close to TC4 possesses the highest microhardness value.

The effect of thermal cycle on joint of Ti/stainless steel phase transformation diffusion bonding

The effects of thermal cycle parameters on the tensile strength and fracture characteristics of phase transformation diffusion bonding(PTDB) joint of titanium and stainless steel (Ti/SS) were studied in this paper. With the maximum cyclic temperature of 1 173～1 223 K , the minimum cyclic temperature of 1 073～1 093 K , the heating velocity of 30～50 K/s , the cooling velocity of 15～20 K/s , the cycle numbers of 15～20 and bonding pressure is 13 MPa , the tensile strength of joint is more than 380 MPa , exceeding 80% of that of Ti.