Diffusion bonding of alumina to steel using soft copper interlayer

The diffusion bonding of a low steel to alumina has been studied in the present work. Thin foils of a soft metal (copper) were used to reduce the effects of the residual stresses produced in the joint by thermal expansion mismatch. The strength of the joint was found to be influenced by the bonding parameters, but principally by the oxygen content both on the surface and in the copper matrix. The diffusion bonds have been mechanically tested using a three-point bending test. Maximum bending strengths of 100 MPa were achieved by using a 0.1 mm copper foil, and bonding in a oxidizing atmosphere (P _{O 2}=10₄Pa). SEM and EDS investigations have shown the presence of reaction products in the copper-alumina interface which controls the mechanical properties of the joint.     

Diffusion bonding of titanium alloy to micro-duplex stainless steel using a nickel alloy interlayer: Interface microstructure and strength properties

In the present study, diffusion bonding of titanium alloy and micro-duplex stainless steel with a nickel alloy interlayer was carried out in the temperature range of 800–950 °C for 45 min under the compressive stress of 4 MPa in a vacuum. The bond interfaces were characterised by scanning electron microscopy, electron probe microanalyzer and X-ray diffraction analysis. The layer wise Ni₃Ti, NiTi and NiTi₂ intermetallics were observed at the nickel alloy/titanium alloy interface and irregular shaped particles of Fe₂₂Mo₂₀Ni₄₅Ti₁₃ was observed in the Ni₃Ti intermetallic layer. At 950 °C processing temperature, black island of β-Ti phase has been observed in the NiTi₂ intermetallics. However, the stainless steel/nickel alloy interface indicates the free of intermetallics phase. Fracture surface observed that, failure takes place through the NiTi₂ phase at the NiA–TiA interface when bonding was processed up to 900 °C, however, failure takes place through NiTi₂ and β-Ti phase mixture for the diffusion joints processed at 950 °C. Joint strength was evaluated and maximum tensile strength of ∼560 MPa and shear strength of ∼415 MPa along with ∼8.3% ductility were obtained for the diffusion couple processed at 900 °C for 45 min.     

Vacuum hot roll bonding of titanium alloy and stainless steel using nickel interlayer

Abstract

Vacuum hot roll bonding of titanium alloy and stainless steel using a nickel interlayer was investigated. No obvious reaction or diffusion layer occurs at the interface between stainless steel and nickel. The interface between titanium alloy and nickel consists of an occludent layer and diffusion layers, and there are the intermetallic compounds (TiNi₃, TiNi, Ti₂Ni and their mixtures) in the layers. The total thickness of intermetallic layers at the interface between titanium alloy and nickel increases with the bonding temperature, and the tensile strength of roll bonded joints decreases with the bonding temperature. The maximum tensile strength of 440·1 MPa was obtained at the bonding temperature of 760°C, the reduction of 20% and the rolling speed of 38 mm s^–1.     

Diffusion bonding stainless steel to alumina using aluminium interlayers

A study has been conducted to identify the effects of fabrication temperatures pressures, times and other variables on the strengths of diffusion-bonded joints between alumina and BS321 stainless steel produced using aluminium foil interlayers. The strengths of the alumina-aluminium and steel-aluminium interfaces were found to be influenced differently by some fabrication parameters, thus increasing the fabrication temperature promoted alumina-aluminium bonding but also accelerated the growth of ultimately weakening intermetallic layers at steel-aluminium interfaces. It was concluded that the optimum conditions for bonding BS321 stainless steel to alumina could be achieved by using a 0.5 mm aluminium foil, applying a 50 MPa pressure for 30 min in an evacuated chamber at 625° C. In discussing the results of this study, attention is paid to the problems or advantages of using foils and metal components other than aluminium or BS321 steel and particular note is taken of thermal expansion mismatch effects.     

Microstructural development of diffusion-brazed austenitic stainless steel to magnesium alloy using a nickel interlayer

The differences in physical and metallurgical properties of stainless steels and magnesium alloys make them difficult to join using conventional fusion welding processes. Therefore, the diffusion brazing of 316L steel to magnesium alloy (AZ31) was performed using a double stage bonding process. To join these dissimilar alloys, the solid-state diffusion bonding of 316L steel to a Ni interlayer was carried out at 900 °C followed by diffusion brazing to AZ31 at 510 °C. Metallographic and compositional analyses show that a metallurgical bond was achieved with a shear strength of 54 MPa. However, during the diffusion brazing stage B₂ intermetallic compounds form within the joint and these intermetallics are pushed ahead of the solid/liquid interface during isothermal solidification of the joint. These intermetallics had a detrimental effect on joint strengths when the joint was held at the diffusion brazing temperature for longer than 20 min.     

Diffusion bonding between Ti -6Al -4V alloy and microduplex stainless steel with copper interlayer

Abstract

In the present study, diffusion bonding was used to join Ti -6Al- 4V alloy to a microduplex stainless steel using a pure copper interlayer. The effects of heating rate and holding time on microstructural developments across the joint region were investigated. After bonding, microstructural analysis including metallographic examination and energy dispersive spectroscopy (EDS), microhardness measurements, and shear strength tests were carried out. From the results, it was seen that heating rate and holding time directly affect microstructural development at the joint, especially with respect to the formation of TiFe intermetallic compounds, and this in turn affects the shear strength of the bonds. A sound bond was obtained with a heating rate of 100 K min ^-1 and holding time of 5 min, and this was related to the small amount of TiFe intermetallics formed close to the duplex stainless steel side at this bonding condition. Although Ti₂Cu and TiFe intermetallics were formed in all specimens, it was seen that the most deleterious intermetallic was TiFe. As the heating rate was decreased and holding time increased the amount of TiFe intermetallics increased, and consequently shear strength decreased. As a result, from the microstructural observations, EDS analysis, microhardness measurements, and shear strength tests, it was concluded that a high heating rate and a short holding time must be used in the diffusion bonding of Ti-6Al- 4V to a microduplex stainless steel when pure copper interlayers are used.     

Diffusion bonding of AZ91 using a silver interlayer

Diffusion bonding of AZ91 alloy with a silver interlayer was carried out at 480 °C for different times under 1 MPa in a vacuum of 2 × 10⁻³ Pa. Shear test was applied to measure the shear strengths of the joints in the room temperature. The shear strength values of all bonded samples were found around 65–70 MPa. SEM–EDS studies indicated that the melting occurred along the interface of bonded samples as a result of transfer of atoms between the interlayer and the matrix during bonding. XRD results confirmed that the interlayer dissolved in the interface of joints. Investigations of the fracture surfaces showed that a good bonding was obtained by plastic deformation.     

Diffusion bonding of titanium alloy to stainless steel wire mesh

Abstract

The feasibility and appropriate processing parameters of diffusion bonding of titanium alloy to stainless steel wire mesh directly and with a nickel interlayer have been investigated. The microstructures of the diffusion bonded joints were observed by optical microscopy, scanning electron microscopy, X-ray diffraction, and electron probe microanalysis and the main factors affecting diffusion bonding were analysed. The maximum shear strengths of the joints were 72 and 148 MPa for direct bonding and indirect bonding using a nickel interlayer respectively. Atomic diffusion and migration between titanium and iron are effectively prevented by adding pure nickel as the interlayer metal, and a firm joint is obtained.     

Hot pressing diffusion bonding of a titanium alloy to a stainless steel with an aluminum alloy interlayer

The probability and appropriate processing parameters of hot pressing diffusion bonding (HP–DW) of a titanium alloy (TC4) to a stainless steel (1Cr18Ni9Ti) with an aluminum alloy (LF6) interlayer have been investigated. The microstructure of the bonded joints has been observed by optical microscopy, SEM, XRD and EDX, and the main factors affecting hot pressing and diffusion bonding process were analyzed. The results showed that atom diffused well and no intermetallic compound or other brittle compounds appeared at optimum parameters. The fracture way of joints was ductile fracture. With the increment of bonding temperature, large number of intermetallic compounds such as FeAl₆, Fe₃Al, FeAl₂ which were brittle appeared along the interface between the stainless steel and the aluminum alloy interlayer, as a result, the quality of joints was decreased significantly and the fracture way of joints was brittle fracture.     

Diffusion bonding of zirconia to silicon nitride using nickel interlayers

The possibilities of diffusion bonding of zirconia to silicon nitride using a nickel interlayer were studied by carrying out bonding experiments under various processing conditions. The process parameters considered were temperature, bonding pressure and interlayer thickness. The optimal process conditions were determined by evaluating the mechanical strength using shear strength testing. It was found that the bonding is optimal in the temperature range 1000–1100°C. The bond strength appears to be independent of the bonding pressure and interlayer thickness if threshold values are exceeded (bonding pressure >14 MPa, interlayer thickness >0.2 mm). At the Si3N4 Ni interface, Si3N4 decomposes, forming a solid solution of silicon in nickel. At the ZrO2–Ni interface, no reaction was observed. © 1998 Kluwer Academic Publishers     

Diffusion bonding between commercially pure titanium and micro-duplex stainless steel

Diffusion-bonded joints between commercially pure titanium and micro-duplex stainless steel were prepared in the temperature range of 800–950 °C for 1.5 h under 3 MPa uniaxial load in vacuum. The diffusion bonds were characterized using light and scanning electron microscopy. The composition of the reaction products were determined by energy dispersive spectroscopy. Up to 850 °C, -Fe + λ and λ + FeTi phase mixtures were formed at diffusion interface; however -Fe + λ, λ + FeTi and FeTi + β-Ti phases mixtures were formed at 900 °C and above. The presence of these intermetallics was confirmed by X-ray diffraction technique. The maximum tensile strength of 96% of Ti and shear strength of 81% of Ti along with 6.9% ductility were obtained for the diffusion couple processed at 850 °C due to the finer width of intermetallic phases. With a rise in the joining temperature the bond strength drops owing to an increase in the width of reaction products.     

Diffusion bonding behaviour of austenitic stainless steel containing titanium and alumina

A study has been conducted to identify the function of titanium in 1 Cr18Ni9Ti steel and the effects of fabrication temperature, pressure, time and other variables on the strengths of diffusion-bonded alumina-1Cr18Ni9Ti. At temperatures of 750 to 1200°C, 1Cr18Ni9Ti steel was successfully bonded to alumina, with a maximum tensile strength of 19MPa. By EPMA titanium segregated to the interface of the joint, in contrast to the failure of bonding of 1Cr18Ni9 steel and alumina under the same conditions. Titanium can reduce alumina with the reactants of TiO and compounds of titanium and aluminium thermochemical calculation. Thus it is indicated that titanium is an important go-between element for bonding metal to alumina.     

Diffusion bonding of Ti coated Zircaloy-4 and 316-L stainless steel

Diffusion bonding of Zircaloy-4 and Type 316-L stainless steel was carried out by coating the joining surfaces with Ti to minimize the interlayer effect. Bonding heat treatments were carried out in vacuum at 1000 °C for 4 h and 1050 °C for 1 h. The microstructure of the diffusion zone was investigated by scanning electron microscopy and the phases in the diffusion zone were analyzed by energy dispersive spectroscopy. It is observed that Ti coating at the interface produced a dendritic structure in the diffusion zone formed in the Zircaloy-4. The concentration of the dendrites increases with an increase in bonding temperature.     

Diffusion bonding of electroless Ni plated WC composite to Cu and AISI 316 stainless steel

In this study, a composite containing WC (Tungsten Carbide) and Ni was produced by two different processing routes. Electroless Ni coated WC powders were consolidated and sintered at 1200 °C. Diffusion bonding couples of WC(Ni)-electrolytic Cu, WC(Ni)-AISI 316 stainless steel and WC(Ni)-WC(Ni) were manufactured by using a preloaded compression system under Ar atmosphere. Diffusion bonding was carried out at varying bonding temperatures; 750 °C for (WC)Ni-Cu diffusion couple and 1200 °C for (WC)Ni-(WC)Ni and (WC)Ni-AISI 316 stainless steel diffusion couples. Standard metallographic techniques, Scanning Electron Microscopy and a shear test were employed to characterize the microstructure of bondline and mechanical properties of each diffusion couple, respectively.     

Structure and properties of diffusion bonded transition joints between commercially pure titanium and type 304 stainless steel using a nickel interlayer

The solid-state diffusion bonding was carried out between commercially pure titanium and Type 304 stainless steel using nickel as an interlayer in the temperature range of 800–900 °C for 9 ks under 3 MPa load in vacuum. The transition joints thus formed were characterized in the optical and scanning electron microscopes. The inter-diffusion of the chemical species across the diffusion interfaces were evaluated by electron probe microanalysis. TiNi₃, TiNi and Ti₂Ni are formed at the nickel–titanium (Ni–Ti) interface; however, the stainless steel–nickel (SS–Ni) diffusion interface is free from intermetallic compounds up to 850 °C temperature. At 900 °C, the Ni–Ti interface exhibits the presence of α-β Ti discrete islands in the matrix of Ti₂Ni and λ + χ + α-Fe, λ + FeTi and λ + FeTi + β-Ti phase mixtures occur at the SS–Ni interface. The occurrence of different intermetallics are confirmed by the x-ray diffraction technique. The maximum tensile strength of ∼276 MPa and shear strength of ∼209 MPa along with 7.3% elongation were obtained for the diffusion couple processed at 850 °C. At the 900 °C joining temperature, the formation of Fe–Ti base intermetallics reduces the bond strength. Evaluation of the fracture surfaces using scanning electron microscopy and energy dispersive spectroscopy demonstrates that failure takes place through Ni–Ti interface up to 850 °C and through the SS–Ni interface of the joint when processed at 900 °C.     

Transient liquid phase bonding of a microduplex stainless steel using amorphous interlayers

Abstract

Microduplex stainless steels are two phase alloys which show excellent corrosion resistance and toughness. In order to join these special steels, fusion welding processes are normally used and a second post-weld heat treatment is necessary to regain the original ferrite to austenite ratio. In this study, transient liquid phase diffusion bonding was used to join a 2205 duplex stainless steel with the aid of amorphous interlayers. The research compares a Ni–B–Si ternary system with that of an Fe–B–Si interlayer, and compositional, microstructural and mechanical assessment was used to determine the quality of the bonds produced. These preliminary results show that the nickel based interlayer stabilises the austenitic phase along the bond length, which hinders grain growth across the joint region. In contrast, the iron based interlayer produces diffusion bonds, which show microstructural and compositional homogeneity across the joint region. Furthermore, mechanical and pitting corrosion tests show that transient liquid phase diffusion bonds can achieve properties similar to those of the parent alloy.     

Solid-state bonding of alumina to austenitic stainless steel

A low temperature and low pressure bonding process for alumina and 316L austenitic stainless steel has been developed using a titanium/molybdenum laminated interlayer. The intermetallic compounds of Ti₃Al (or Ti₂/Al) and TiAl were formed at the alumina/titanium interface on bonding at above 1273 K. The activation energy of the layer growth was about 142 kJ mol^–1. The construction of Al₂O₃/Ti/Mo/steel gave the most stable joints. The highest tensile strength was above 60 MPa with a titanium 0.4 to 0.6mm thick/molybdenum 0.4 to 0.5 mm thick interlayer on bonding at 1273 K for 3 h under pressure of 12 MPa.     

Transient liquid phase bonding of steel using an Fe–B interlayer

Transient liquid phase bonding processes have been performed to join two carbon steel tubes using Fe_96.2B_3.8 wt% amorphous ribbons as interlayers. Welding experiments were performed at the temperature T ≈ 1,250 °C for different durations and under pressures of 2, 3 and 4 MPa. From metallographic inspection it is concluded that the bonding process ends in 7.0 min if a pressure of 4 MPa is applied whereas the process results incomplete if less pressure is applied. A 1D model using a finite element method has been developed for the simulation of a transient liquid phase bonding process. This model was applied to the bonding of steel/Fe–B glassy metals/steel. The computed results allow us to understand the role played by the variables involved in the bonding process.     

Effect of Cr interlayer on the adhesion and corrosion enhancement of nanocomposite TiN-based coatings deposited on stainless steel 410

Applications of hard protective nanocomposite coatings are frequently limited by insufficient adhesion related to high stress. In the present work, we study the effect of an intermediate Cr layer on top of the stainless steel 410 (SS410) substrate on the performance of the nanocomposite (nc) TiN-based coatings prepared by plasma enhanced chemical vapor deposition. The Cr layer was found to enhance the corrosion resistance of the SS410 substrate by a factor of 280 in terms of corrosion current, and to increase adhesion of the TiN coating by a factor of 4. We show that for the nc-TiN/a-SiN_x and nc-TiCN/a-SiCN coatings, the substantial improvement of the corrosion resistance can be attributed to the combination of the inertness of the Cr layer, and of the densely packed homogeneous nc structure of the nc coatings containing Si and/or C in comparison to columnar crystalline TiN coatings.