Presentation on:- Diffusion Bonded

Welding
(DBW)

Table Of Content

INTRODUCTION
CHARACTERSTICS
WORKING PRINCIPAL
WORKING PROCESS
EXPERIMENTAL PROCEDURE
FACTORS INFLUENCING DIFFUSION WELDING
FILLER MATERIAL
MATERIALS IN DIFFUSION WELD
ADVANTAGES
LIMITATIONS
APPLICATIONS
REFERENCES

Diffusion WELDING: Diffusion welding (DFW) is a solid state welding process by which
two metals (which may be dissimilar) can be bonded together.

Diffusion involves the migration of atoms across the joint, due to

concentration gradients. The two materials are pressed together at
an elevated temperature usually between 50 and 70% of the
melting point.

The pressure is used to relieve the void that may occur due to the
different surface topographies.
The pressure used is in the range of 35 to 70 MPA.

CHARACTERISTICS

It operates on thematerials scienceprinciple of solidstatediffusion, wherein the atoms of two solid,

metallic surfaces intermingle over time under elevated
temperature. Diffusion bonding is typically
implemented by applying both high pressure and high
temperature to the materials to be welded.

Diffusion welding use for metal to metal and metal to

nonmetals.
The characteristic features of this process are that it
does not introduce macroscopic deformations or
relative motion in either of the welded parts and that

CHARACTERISTICS
Diffusion bonding is mostly used for jobs either
difficult or impossible to weld by other source.
Exp: zirconiumandberyllium; titanium and
copper, materials with very high melting points..
Diffusion bonding involves no liquid fusion or filler
metal.
The join tends to exhibit both the strength and
temperature resistance of the base metal.

Diffusion Welding Working Principles

Diffusion Welding Working Principles

1st stage
deformation forming interfacial boundary.

2nd stage
Grain boundary migration and pore
elimination.

3rd stage
Volume diffusion and pore elimination.

PRINCIPAL

Process
At the microscopic level, diffusion bonding occurs
in three simplified stages: Before the surfaces completely contact,asperities(very small
surface defects) on the two surfaces contact at the microscopic
level and plastically deform. As these asperities deform, they
interlink forming interfaces between the two surfaces.
Elevated temperature and pressure causes acceleratedcreepin
the materials;grain boundariesand raw material migrate and
gaps between the two surfaces are reduced to isolated pores.
Material begins todiffuseacross the boundary of the abutting
surfaces, confusing this boundary and creating a bond.

Process

Working Process
Diffusion bonding is performed by clamping the two
pieces to be welded with their surfaces each other.
Prior to welding, these surfaces must
bemachinedto as smooth afinishas economically
viable, and kept as free from chemical contaminants
or other detritus as possible.
Any intervening material between the two metallic
surfaces may prevent adequate diffusion of
material. Once clamped, pressure and heat are
applied to the components

EXPERMENTAL PROCEDURE
For this purpose, titanium and copper materials joined
through diffusion welding method.
The specimens for the diffusion welding (Ti and Cu) were
prepared in the sizes of 10 mm in diameter and 10 mm in
length.
The prepared specimens were ground with SiC abrasive
papers of various grit sizes (240, 400, 800 and 1200) and
polished to mirror surface finish using a 1 m diamond
paste.
Finally, all the specimens were cleaned by degreasing in
acetone.

EXPERMENTAL PROCEDURE

Diffusion welding was made in an argon atmosphere in the

bonding chamber equipment.

In order to eliminate the oxidation problem, Ar gas was

introduced into the test chamber 5 min before the welding
and kept (continued) during welding.
3 MPa pressure was applied during the diffusion bonding.
Important diffusion bonding process parameters (bonding
temperature and holding time) were identified in Table by
carrying out preliminary tests.
Heating and cooling rates of 20 C/min were employed during
the heating and cooling cycles.

Diffusion welding equipment

(a) photo and (b) schematic.

EXPERMENTAL PROCEDURE
When the bonding process was completed, the
specimens were cooled to room temperature in the
furnace.

Factors Influencing
Diffusion Welding

(Relation between Temperature and Diffusion Coefficient)

Temperature
D = D0 e -Q/KT

D = Diffusion coefficient
D0 = Diffusion constant
Q = Activation energy
T = Absolute temperature
K = Boltzmans constant

4.
X = C (Dt)1/2 = Diffusion Length
X = Diffusion length
C = A constant
D = Diffusion coefficient (see previous slide)
t =Time

Factors Influencing
Diffusion Welding
The diffusion can be achieved when one keeps two
pieces in intimate contact under pressure.
By using heat, the bonding time can be further reduced
as the diffusion process gets accelerated through heat.
The heat applied is much lower than the melting points
of
metals.

The pressure needs to be kept optimum such that

there is no
plastic deformation.

Filler Material
A filler material can be used and is kept between the two
metals to be joined.(silver layer,nikel layer)

The filler material if used its thickness is in the range of 5 to 25 microns only.

In such a case it is expected that the temperature required for bonding is

reduced by the formation of a eutectic alloy.

Thus, the filler metal diffuses into the two metal plates and forms a eutectic
joint.

Although filler metal is in principle not required for Diffusion welding, it

has been found that a foil of suitable materials placed at the interface
can sometimes facilitate the process.

Materials In Diffusion Weld

It Can be Diffusion welded Titanium alloys, nickel
alloys, aluminum alloys, as well as different
combinations of materials not easily joined by
traditional means.
Steels are preferably welded by alternative more
economic methods.
But large, flat surfaces of low carbon steel have been
Diffusion welded without filler metal under the proper
conditions

Advantages
This solid state process avoids pitfalls of fusion welding .
Dissimilar materials welds are possible.
Properties and microstructures remain similar to those of base
metals.
Multiple welds can be made in one setup at the same time.
Produces a product finished to size and causes minimal
deformation.

Presents less shrinkage and stresses compared to other

welding process.

Highly automated process does not need skillful workforce.

Limitations

Costly equipment especially for large weldments.

Costly preparation with smooth surface finish and exceptional

cleanliness.

Protective atmosphere or vacuum required.

Long time to completion.

Not suited to high production rates.

Difference in thermal expansion of members may need special

attention.

Limited nondestructive inspection methods available

APPLICATION
Application in titanium welding for aero-space
vehicles.
Diffusion welding of nickel alloys include Inconel
600, wrought Udimet 700, and Rene 41.
Dissimilar metal diffusion welding applications
include Cu to Ti, Cu to Al, and Cu to Cb-1%Zr.
Brittle intermetallic compound formation must be
controlled in these applications.

BIBILOGRAPHY
http://www.sciencedirect.com/science/article/pii/S
0261306912000350
(Kemal Aydn , Yakup Kaya , , Nizamettin
Kahraman)
http://www.sciencedirect.com/science/article/pii/S02
61306904001967
Wikipedia
Google

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