Presentation

On
Diffusion Welding &
Latest trends
SHWETA
ROLL NO:3143512
INDUSTRIAL & PRODUCTION

CONTENTS:
Introduction
Diffusion
Main

welding technology

obstacle of process

Mechanism
Methodology
Process

variables

Comparison
New

between diffusion and friction welding

trend in diffusion welding

Advantages
Applications
Limitations
Case

studies

References

Introduction:
Historical Development- In 1970 Goldsmith had developed this
technique to bond gold over copper and named it as filled gold.
Definition-It is solid state welding wherein coalescence of faying
surface is produced by the application of pressure and elevated
temperatures.
Purpose-Most efficient method to join two dissimilar materials.
Materials joined include- Aluminum , copper ,ceramics , inconel
alloys , nickel , platinum , stainless steel , titanium.(1)

Diffusion Welding Technique

Subdivision of both solid-state welding and liquid-phase
welding
Strength of joints primarily from movement of atoms across
interface and secondarily from plastic deformation of faying
surfaces
Requires temperature about 0.5Tm
Conducted under a vacuum of 10^(-3)-10^(-5) mbar or in an
inert atmosphere (normally dry nitrogen, argon or helium).
(1)

Main obstacle in process

polished surfaces come into contact only at their asperities
and hence the ratio of contacting area to faying area is very
low.
Secondly in certain materials, the presence of oxide layers at
the faying surfaces will affect the ease of diffusion bonding.

Methods to overcome obstacleImposing substantial plastic deformation

Enhancing microplastic deformation of the surface asperities
Presence of active alloying elements and use of interlayers.
(2)

Mechanism(8)

Methodology
Diffusion Bonding OvenCreates vacuum chamber with a pump capable of reducing
the internal pressure up to 8x10^(-7)mbar.
The pressing system used to apply loads upto 16 tons and
the heating system can raise the inside temperature to about
1000C.
The equipment allows the control of all process variables

Method-Once the atmosphere inside the chamber stabilized,

the oven power controller was turned on and furnace get heated
at the desired rate , which varied from sample to sample.(7)

SS/Al diffusion bonding welded

sample(7)

Diffusion bonding oven in

BARC(7)

Process variables
There are total five process variables:
Surface preparation
Temperature
Time
Pressure
Use of interlayers(8)

(8)

Criteria for selection of interlayers

The chemical composition of the bonded materials.
Possibility of alloy formation.
Good weldability in radiation or induction heating in vacuum
or a controlled atmosphere.
Metallurgical compatibility of bonded materials with the
material of the interlayer.
The unstable state of the surface as a result of high
defectiveness of the structure (linear, volume, planar &
point effects, including inclusions, pores, vacancies,
dislocations.

Comparison between Friction &

Diffusion Welding(4)
Diffusion welding

Friction welding

Takes longer time in hours

Takes less time in seconds

Smoother joints

Comparatively less smoother

Intermetallic phase stay at cu

Intermetallic phase of cu at Al

side

side

Less joint strength

More joint strength

New trends in diffusion welding

Transient Liquid Phase Diffusion Bonding
Formation of liquid phase at bond line
Liquid phase then infuses the base material and solidifies
Diffusion rate in liquid phase enhances dissolusion and
distortion of oxide layer and hence promote intimate
contact surfaces
Hence presence of liquid reduces required pressure
Formation of a liquid phase in TLP diffusion bonding could
assist the disruption of an oxide layer and thus promote
metallic contact.(2)

Fabrication of monoblock high heat

flux components
Monoblock concept is used in international thermonuclear
reactor (ITER)
The fabrication of monoblocks is difficult due to the thermal
expansion mismatch between copper alloy and tungsten.
Direct joints are reported to be weak.
New technology named as Hot Isostaic Pressure welding
developed.
Hot Isostatic Pressure(HIP): Isostatic gas pressure created
at elevated temperature in a container where diffusion welding
is to be performed. Pressurizing gas mostly used are argon.

Study on liquid-phase-impact diffusion

welding(LPIDW) SiCp /ZL101
Aluminum matrix composite has a wide application in the
fields of aerospace, automobile and so on, because of their
high specific strength, rigidity, wear resistance and good
dimensional stability.
Composition of ZL101 is 25% silicon and 55% aluminum.
First of all, the LPIDW temperature was between solid phase
and liquid-phase. When the ratio of liquid matrix alloy was up
to certain value at the jointing area, the jointing area was
impacted in short time (about 10^(-4)10^(-2) s)
synchronously. As a result, SiCp /ZL101 could be jointed
successfully.(6)

AdvantagesProduce high quality joints i.e. free of discontinuities and

porosity at interface
strength and ductility equivalent to those of the parent
material.
Metals ,alloys, ceramics and powder metallurgy products can
be joined.
Good dimensional tolerances
intricate shapes or cross sections is possible.
Heavy section parts can be joined by diffusion bonding
without pre-heating.
Reduction of sensitivity to corrosion has been reported in
some diffusion bonded alloys e.g. titanium and zirconium
Free from U V radiation and gas emission hence no direct
detrimental effect on the environment, and health and safety
Automation is possible by computer controlling the basic
variables of the diffusion bonding e.g. time, temperature,
and pressure.(2)

Applications
Aero jet Space Shuttle valve assemblies
Copper cold plates and flexible thermal straps for cooling
Heat exchangers
Major medical device corporation artificial heart implant
components
Fabrication of nuclear reactors components, and heat
exchangers
NASA Bonding parameter development for Mars Lander
Robotic assemblies for submarines used in offshore oil
industry
Super alloy structures measuring 24 by 24 by 27 inches
encapsulating miles of micro channels and other.(2)

Various parts in aeroplane(1)

Various superalloys

Superalloys(2)

Fabrication of electronic items

Thermo compression bonding is well established in theCMOS

(complementary metal oxide semiconductor)industry and realizes
vertical integrated devices and production of wafer level packages
with smaller form factors.(2)

LimitationsGreat care required for surface preparation

Application of the force and heat in a vacuum or protective
environment makes onsite working difficult.
Not suitable for mass production.(1)

Case study 1
Diffusion bonding technique are being used for various following
applications at BARC 2013:

Diffusion bonding of aluminum to stainless

steelJoining of Al and its alloys to SS 304 is frequently
required in cryogenic and nuclear applications. This requires a
transient joint between these two alloys.

Welding and brazing of these alloys are difficult due to large

differences in their melting points, thermal expansion
coefficients and thermal conductivities

Friction and explosion welding joints generally result in the

development of large residual. stress and structural discontinuity
at interface.
Diffusion bonding offers sound strength and high leak-tight joint
when silver interlayer was used. Successful Al/SS joints were
prepared by diffusion.(5)

(a) Stainless steel / aluminium joint assembly diffusion bonded

with interlayers at 350 oC for 2 h used in neutron counters (b) micrograph
showing the transition interface between the two base materials

Manufacturing of perforated plate matrix

heat exchanger for cryogenic applicationPerforated plate matrix heat exchanger is a compact and highly
effective heat exchanger for liquifying of helium in cryogenic
application. The heat exchanger essentially consists of a stack
of perforated copper plates alternating with stainless steel (SS)
spacers. The diffusion bonded joint between Cu/SS has been
developed, to fabricate a cryogenic matrix heat exchanger.
Stacks consisting of plates and spacers (75 each) and two
stainless steel end plates were bonded to form monolithic heat
exchanger.(5)
Alternate layers of Cu plates and
stainless steel spacers along with two
end plates diffusion bonded to form a
matrix heat exchanger for cryogenic
applications,

Case study 2

Exit hatch for the British

Aerospace BAE 125/800
in 2001:
This process has proven particularly useful when combined with
the superplastic forming (SPF) of titanium alloys. The
conventional fabrication consisted of 16 parts held together by
500 fasteners. It was proposed to replace that design by a 2sheet assembly, integrally stiffened produced by SPF/DFW. The
application of SPF/DFW reduces the original riveted aluminum
design from 76 detail parts and 1000 fasteners to a titanium
version with only 14 details and 90 fasteners with a total cost
savings of 30%. (3)

Conventional structure and integrated plan for

door panel using SPF/DFW25.

References:
1.
2.

Kalpakjian manufacturing engineering and technology

Diffusion Bonding Aluminum Alloys and Composites: New
Approaches and Modelling Thesis of Amir A. Shirzadi ,Kings
College Cambridge, december 1997.

3.

Patricio F. Mendez Massachusetts Institute of Technology

Cambridge, MA 02139, USA

4.

BAU Fen Bilimleri Enstitusu Dergisi (1999). 1 (2),Department

of Mechanical Engineering, 10100, Balkesir, Turkiye

5.

Research article of BARC, April 2013

6.

Sciencedirect.com

7.

F.E Manoel LNLS, Campinas, Brazil, DEVELOPMENT OF

DIFFUSION BONDING JOINTS BETWEEN OXYGEN FREE COPPER
AND AISI 316L STAINLESS STEEL FOR ACCELERATOR
COMPONENTS

8.

myothitsan.files.wordpress.com/2012/10/diffusion-welding.pdf

THANK
YOU