Formation process of the bonding joint in Ti/Al diffusion bonding

The process of the formation of Ti/Al diffusion bonding joints was studied by means of scanning electron microscopy (SEM), X-ray diffractometry (XRD) and shear strength measurement. Pure titanium and pure aluminum were used as bonding couples. The results show that the process of joint formation can be separated into four stages, and the product of the diffusion reaction is only TiAl₃ under a particular range of holding time. There is a delay time t_D before TiAl₃ is generated, which is mainly affected by temperature. The joint strength depends on the metallurgical combination percentage and the interface structure in the diffusion zone, and it can reach or even exceed the strength of pure aluminum after TiAl₃ forms a layer. The position where shear fracture occurs depends on interface structure in the diffusion zone.     

Diffusion bonding of Fe-28Al(Cr) alloy with low-carbon steel in vacuum

Fe-28Al(Cr) alloy and low-carbon steel were diffusion bonded in a vacuum of 10⁻⁴-10⁻⁵ Pa. The relationship of the bond parameters and shear strength at the interface was discussed. Microstructure characteristics and the reaction products at the interface were investigated by scanning electron microscopy (SEM) and X-ray diffractometry (XRD). The thickness of the diffusion reaction layer was measured with electron probe microanalysis (EPMA). The results indicated that controlling bonding temperature 1333 K for 3.6 ks, shear strength at the interface can be up to 112 MPa. Three kinds of reaction products were observed to have formed during the vacuum diffusion bonding, namely FeAl, Fe₃Al and α-Fe (Al) solid solution. The thickness (X) of the diffusion reaction layer increases with bonding time (t) according to a parabolic law X²=6.4×10³ exp(−104.1/RT)(t-t₀) (μm²).     

XRD and SEM analysis near the diffusion bonding interface of Mg/Al dissimilar materials

The microstructure and phase constitution near the diffusion bonding interface of Mg/Al dissimilar materials are studied using a scanning electron microscope (SEM), X-ray diffraction (XRD) and transmission electron microscope (TEM). The test results indicated that an obvious diffusion zone was formed near the Mg/Al interface during the vacuum diffusion bonding. The diffusion transition zone near the interface consists of various Mg_xAl_y phases. The transition region on the Mg side mainly consists of Mg crystals, and the new phase formed was the Mg₃Al₂ phase having a face-centred cubic lattice. This is favorable for improving the combined strength of Mg substrate and diffusion transition zone.     

Friction stir weld assisted diffusion bonding of 5754 aluminum alloy to coated high strength steels

In the present paper friction stir-induced diffusion bonding is used for joining sheets of 5754 aluminum alloy to coated high strength steels (DP600 and 22MnB5) by promoting diffusion bonding in an overlap configuration. Mechanical performance and microstructures of joints were analyzed by overlap shear testing, metallography, and X-ray diffraction. Our results show that the strength of joint is dependent upon tool travel speed and the depth of the tool pin relative to the steel surface. The thickness and types of intermetallic compounds formed at the interface play a significant role in achieving a joint with optimum performance. That is, the formation of high aluminum composition intermetallic compounds (i.e. Al₅Fe₂) at the interface of the friction stir lap joint appeared to have a more negative effect on joint strength compared to the presence of high iron composition intermetallic phases (i.e. FeAl). This is in agreement with previously reported findings that FeAl intermetallic can improve the fracture toughness and interface strength in Al/St joints.     

Superplastic diffusion bonding of γ-TiAl-based alloy

With laser surface melting and conventional heat treatment, superplastic diffusion bonding of TiAl alloy samples was carried out. Three different microstructure, i.e. fully lamellar structure, fine dendritic structure and refined equiaxed structure are used and their effects on bonding quality were investigated, and the bond quality was assessed by shear test at room temperature. Sound bonds could be achieved at 900 °C by laser surface modification or by laser surface modification and pre-bond heat treatment at 1000 °C for 60 min, which is lower than conventional diffusion bonding temperature. The bonds were also post-bond heat treated at 1200 °C for 30 min, which improved the bond quality in all cases. The best shear strength of the bonds is greater than 80% of that of base metal.     

A study on diffusion bonding of steel and copper alloy

In combustion chamber of liquid propellant launch vehicle, the inner shell of the chamber is copper alloy with cooling channels for regenerative cooling and outer shell is steel to maintain high pressure inside the chamber. The purpose of this study is to find the optimum condition for diffusion bonding of copper and steel and the experimental conditions were 3 different pressures at temperatures from 800°C to 950°C. In order to characterize the flow strength of materials at high temperatures, several tensile tests were performed at several temperatures from 800°C to 950°C. This information is used to estimate the test condition for diffusion bonding and superplastic forming. Mechanical properties of bonded specimen were evaluated with single lap joint tests and shear tests. Microstructure of bonded layer has been also observed with SEM with EDX. It is shown that the optimum condition of diffusion bonding is 7 MPa at 890°C, for one hour. Pressurization test of bonded specimen with cooling channels was performed with hydraulic pressure of 87 MPa without failure.     

Characterization of Al/Ni multilayers and their application in diffusion bonding of TiAl to TiC cermet

The Al/Ni multilayers were characterized and diffusion bonding of TiAl intermetallics to TiC cermets was carried out using the multilayers. The microstructure of Al/Ni multilayers and TiAl/TiC cermet joint was investigated. The layered structures consisting of a Ni₃(AlTi) layer, a Ni₂AlTi layer, a (Ni,Al,Ti) layer and a Ni diffusion layer were observed from the interlayer to the TiAl substrate. Only one AlNi₃ layer formed at the multilayer/TiC cermet interface. The reaction behaviour of Al/Ni multilayers was characterized by means of differential scanning calorimeter (DSC) and X-ray diffraction. The initial exothermic peak of the DSC curve was formed due to the formation of Al₃Ni and Al₃Ni₂ phases. The reaction sequence of the Al/Ni multilayers was Al₃Ni → Al₃Ni₂ → AlNi → AlNi₃ and the final products were AlNi and AlNi₃ phases. The shear strength of the joint was tested and the experimental results suggested that the application of Al/Ni multilayers improved the joining quality.     

Al2O3/Cu/Al扩散连接工艺参数的优化

通过一定范围内的强度实验数据建立了Al2O3/Cu/Al扩散连接工艺规范参数优化的数学模型，得到了评价接头综合性能的回归方程。利用该方程求得最佳接头性能的工艺参数为：T＝777K、t=1226s。对该工艺规范扩散连接的Al2O3/Cu/Al接头进行强度试验，接头抗拉强度为108MPa、剪切强度为45MPa。强度试验结果表明，接头获得最佳综合强度值的工艺规范介于获得最大抗拉强度值时的规范与获得最大剪切值时的规范之间。在最佳综合规范下，接头的抗拉强度和剪切强度值与最大抗拉强度、最大剪切强度值接近，这表明数学模型所计算出来的最佳规范与实际值吻合较好。     

Hybrid friction diffusion bonding of aluminium tube-to-tube-sheet connections in coil-wound heat exchangers

The present study presents and evaluates an application of a new solid-state bonding process, hybrid friction diffusion bonding (HFDB). HFDB is used to fabricate tube-to-tube-sheet connections for aluminium coil-wound heat exchangers. An industry-applicable process variant is developed, and its feasibility is demonstrated by gas leak tightness tests and tensile pull-out tests. The joints meet the requirements of industrial applications. Furthermore, the process is characterised by the thermal field development in the weld area and the applied process forces. The microstructure of the joint is investigated, and dynamic recrystallization is assumed to be the primary grain refinement mechanism in the thermo-mechanically affected zone.     

Effect of surface roughness on tribological properties of TiB2/Al composites

55 vol.% TiB₂/2024Al composites were fabricated by pressure infiltration method. The effect of surface roughness of GCr15 steel disc (Ra 0.606, 0.372, 0.023, 0.005 μm) on the tribological properties of composites was investigated. Results showed that with the change of surface roughness, there is an optimal value (Ra 0.023 μm) under which the friction coefficient and wear rate is the lowest. The optimal surface roughness is in the same order of mixture of TiO₂ and B₂O₃, observed on the surface of TiB₂ particles after pre-heating process. During sliding, the filling of this oxidation layer into the asperity gap of GCr15 and greatly reduces adhesion between aluminium and GCr15, furthermore, decreases the friction coefficient and wear rate.     

Ti_3Al超塑性扩散连接的理论计算

研究了Ti3 Al超塑性扩散连接的物理模型和数学模型 ,对Ti3 Al超塑性扩散连接的工艺过程进行了理论计算 ,探讨了工艺参数对Ti3 Al超塑性扩散连接质量的影响 .     

Influence of surface roughness on the bonding quality in twin-roll cast clad strip

Manufacturing of aluminum-steel clad strips by means of twin-roll casting is of great interest due to a shorter production chain in comparison with convenient technologies. Experiments on twin-roll casting of clad strips of pure aluminum and an austenitic stainless steel of 2.5?mm total thickness with the inline abrasive cleaning of a steel substrate’s surface performed. The corresponding device for the inline surface preparation is designed. The influence of surface roughness of the substrate’s surface on the bonding strength between strip layers is analyzed. The mechanism of intermetallic bonding on the roughened surfaces is discussed. It is shown that surface roughness of steel substrate up to 4.2?µm provides bonding strength above 100?MPa.     

Al2O3/Ti6Al4V diffusion bonding joints using Ag–Cu interlayer

Ceramic materials, such us alumina, are widely used for wear resistant and industrial components as in aircraft applications. On the other hand, Ti6Al4V is commonly used for aeronautical applications, due to its superplasticity, low weight and high mechanical resistance but has poor wear resistance because of its low resistance to plastic shearing. For these reasons numerous techniques have been developed to improve its wear resistance including joining to ceramic materials. Ceramics and alloys can be joined by several different processes and the use of an interlayer can further facilitate this process. In the present work Al₂O₃ and Ti6Al4V alloy have been diffusion bonded using a (Ag–Cu) interlayer. Identification of intermetallic phases formed within the bonded region enables the mechanical behaviour of the joints to be explained. These intermetallic phases are related to the bonding conditions applied (750 °C, 3 MPa with bonding times varied from 10 to 60 min).     

钛合金-铜合金组合筒扩散焊配合间隙选择研究

对具有组合筒型的钛合金与铜合金扩散焊配合间隙选择进行了研究 ,建立了能合理反映焊接压力和配合间隙的力学模型 ,以及反映弹性模量和线膨胀系数与温度关系的数学模型 ,确定了给定焊接压力下最佳的间隙配合尺寸 .     

Diffusion bonding of Zr55Cu30Ni5Al10 bulk metallic glass to Cu with Al as transition layer

In this work we demonstrate the diffusion bonding of Zr₅₅Cu₃₀Ni₅Al₁₀ bulk metallic glass (BMG) to aluminum and copper alloy. The process parameters including temperature, pressure and time are investigated experimentally, and we obtain appropriate ones for accomplishing diffusion bonding of the BMG to aluminum alloy successfully. Then we present a two-step diffusion bonding process to bond the BMG to copper alloy by using aluminum alloy as transition layers, and achieve a five-layer bonded joint of BMG/Al/Cu/Al/BMG. The mechanical properties of the multilayer joint are examined. The hardness of the BMG in the joint is enhanced while the bending strength decreases significantly compared with the as-received BMG. Besides, the crystalline metals alleviate and block the extension of cracks in the BMG, which results in the joint fracturing in an explosion-proof glass manner, dissimilar to rupturing in a catastrophic manner that is always happened in the BMGs. Therefore, diffusion bonding of BMG to crystalline metals is a promising way to extend its application.     

Evaluation of interfacial bonding in dissimilar materials of YSZ-alumina composites to 6061 aluminium alloy using friction welding

The interfacial microstructures characteristics of alumina ceramic body reinforced with yttria stabilized zirconia (YSZ) was evaluated after friction welding to 6061 aluminum alloy using optical and electron microscopy. Alumina rods containing 25 and 50 wt% yttria stabilized zirconia were fabricated by slip casting in plaster of Paris (POP) molds and subsequently sintered at 1600 °C. On the other hand, aluminum rods were machine down to the required dimension using a lathe machine. The diameter of the ceramic and the metal rods was 16 mm. Rotational speeds for the friction welding were varied between 900 and 1800 rpm. The friction pressure was maintained at 7 MPa for a friction time of 30 s. Optical and scanning electron microscopy was used to analyze the microstructure of the resultant joints, particularly at the interface. The joints were also examined with EDX line (energy dispersive X-ray) in order to determine the phases formed during the welding. The mechanical properties of the friction welded YSZ-Al₂O₃ composite to 6061 alloy were determined with a four-point bend test and Vickers microhardness. The experimental results showed the degree of deformation varied significantly for the 6061 Al alloy than the ceramic composite part. The mechanical strength of friction-welded ceramic composite/6061 Al alloy components were obviously affected by joining rotational speed selected which decreases in strength with increasing rotational speed.     

Diffusion behavior and reactions between Al and Ca in Mg alloys by diffusion couples

The diffusion behavior and reactions between Al and Ca in Mg alloys by diffusion couple method were investigated. Results demonstrate that Al_2Ca is the only phase existing in the diffusion reaction layers.The volume fraction of Al_2Ca in diffusion reaction layers increases linearly with temperature. The standard enthalpy of formation for intermetallic compounds was rationalized on the basis of the Miedema model. Al-Ca intermetallic compounds were preferable to form in the Mg-Al-Ca ternary system under the same conditions. Over the range of 350–400?C, the structure of Al_2Ca is more stable than that of Al_4Ca, Al_(14)Ca_(13) and Al_3Ca_8. The growth constants of the layer Ⅰ, layer Ⅱ and entire diffusion reaction layers were determined. The activation energies for the growth of the layer Ⅰ, layer Ⅱ and entire diffusion reaction layers were(80.74 ± 3.01) k J/mol,(93.45 ± 2.12) k J/mol and(83.52 ± 1.50) k J/mol, respectively.In layer Ⅰ and Ⅱ, Al has higher integrated interdiffusion coefficients D~(Int, layer)ithan Ca. The average effective interdiffusion coefficients D_(Al)~(eff) values are higher than D_(Ca)~(eff) in the layer Ⅰ and Ⅱ.     

Wear behavior of nanostructured Al/Al2O3 composite fabricated via accumulative roll bonding (ARB) process

In the present work, wear behavior of nanostructured aluminum and composite performed by accumulative roll bonding (ARB) process was investigated. The wear characteristics were studied by scanning electron microscopy (SEM) equipped with energy dispersive spectroscopy (EDS). Also, transmission electron microscopy (TEM) and crystallographic texture investigations were performed. The results indicated that the ARB process led to the decrease in wear resistance of the monolithic and composite samples compared with as-received aluminum strip. The adhesive, abrasive and delaminating wear mechanisms occurred in the monolithic and composite samples simultaneously. At higher number of ARB cycles, delamination was the dominant wear mechanism. It was found that the surface damage of the composite was more extensive than that of the monolithic sample due to the occurrence of spalling mechanism. It was suggested that the intense Rotated Cube {0 0 1}〈1 1 0〉 texture component of composite helped to crack nucleation and propagation greatly. The role of delamination and especially, spalling in decreasing the wear resistance of composite was very important such that it eliminated the role of reinforcing particles and grain size on the wear resistance.     

Effects of heat treatments on the microstructure and mechanical properties of a 6061 aluminium alloy

This paper describes the mechanical behavior of the 6061-T6 aluminium alloy at room temperature for various previous thermal histories representative of an electron beam welding. A fast-heating device has been designed to control and apply thermal loadings on tensile specimens. Tensile tests show that the yield stress at ambient temperature decreases if the maximum temperature reached increases or if the heating rate decreases. This variation of the mechanical properties is the result of microstructural changes which have been observed by Transmission Electron Microscopy (TEM).