DIFFUSION WELDING/BONDING (DFW)

INTRODUCTION
A solid-state welding process that produces
coalescence of the faying surfaces by the
application of pressure at elevated
temperature so that they actually grow
together by atomic diffusion.
The process does not involve macroscopic
deformation or relative motion of the
workpieces.
The process can join either similar or
dissimilar metals with or without the use of
an intermediate material.

Force

Work pieces

A
B

Fig. Schematic representation of

diffusion welding using
electrical resistance for heating

THEORY OF DIFFUSION WELDING

Diffusion welding process involves two stages:
FIRST STAGE
Any smooth surface to be mated may consists of peaks and valleys, it may also
contain an oxidized layer, oil, dirt, absorbed gas etc.
The first stage involves to achieve intimate metal-to-metal contact between the
two pieces to be welded by application of pressure that deforms the surface
roughness and disperses the surface layers and contaminants.
The pressure applied ranges from 350 to 700 kg/cm2.

SECOND STAGE
It involves diffusion and grain growth to complete the weld, eliminates the interface
formed in the previous stage.
The second stage induces complete metallic bonding across the area of contact.
In order to increase diffusion rate, moderate heating temperatures (usually below 1100C)
are used.
Without applying heat if it takes many hours to perform a certain bonding, with the
application of heat, the time element will be cut to a few hours or minutes.
After metal to metal contact is established, the atoms are within the attractive force fields
of each other (and hence a high strength joint is generated). The joint resembles a grain
boundary.

A planer interfacial boundary being thermodynamically unstable, tends to migrate to a

more stable configuration if conditions permit.

STAGES IN DIFFUSION BONDING

MECHANISM

EQUIPMENT FOR DIFUSSION WELDING

Most of the equipment, especially tooling, has to be built specially for the
items to be welded.

Presses or autoclaves should be adapted for providing the required atmosphere

and the needed heat source to the parts, sometimes embedded in ceramic
molds.

A HIGH
PRESSURE
RUPTURE DISK
AUTOCLAVE

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MATERIALS WELDED USING

DIFUSSION BONDING

Titanium alloys, nickel alloys and aluminum alloys can be easily diffusion
welded.

Also, Different combinations of materials not easily joinable by traditional

means.

Steels are preferably welded by alternative more economic methods, but large,
flat surfaces of low carbon steel can be diffusion welded without filler metal
under the proper conditions.

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DIFFUSION WELDING METHODS

1.

Gas pressure bonding

2.

Vacuum fusion bonding

3.

Eutectic fusion bonding

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1. GAS PRESSURE BONDING

Parts to be joined are placed together in intimate contact and then heated to
around 815C.

During heating, an inert gas pressure is built up over all the surfaces of the parts
to be welded.

Non ferrous metals are joined with the help of this method

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2. VACUUM PRESSURE BONDING

Parts to be joined are pressed together mechanical or hydraulic presses

(similar to forging presses).

Heating is carried out the same way as in gas pressure bonding but in a
vacuum chamber.

Pressure is higher than the gas pressure bonding.

Vacuum fusion bonding is used for steel and its alloys. For diffusion bonding
of steel, the temperature and pressure required are approx. 1150C and
700kg/cm2 respectively

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3. EUTECTIC FUSION BONDING

It is a low temperature diffusion welding process.

A thin plate of some other material is used as a filler material and it is kept
between the pieces to be joined.

When the pieces are heated to a elevated temperature the filler material diffuses
and forms an eutectic compound with the parent metals

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DIFFUSION WELDING PARAMETERS

1.

Pressure

2.

Temperature

3.

Time

4.

Surface preparation

5.

Metallurgical factors

6.

Use of inter layers

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1. PRESSURE

Uniform pressure assures consistency of bond formation.

The initial deformation phase of bond formation is directly affected by the

intensity of pressure applied.

For any given time temperature value, increased pressure invariably results in
better joints. However, increased pressures require costlier equipment.

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2. TEMPERATURE
2. Elevated temperature serves the important function of increasing the surface
energy hence the mobility of the atoms.

Temperature affects
Plasticity, Diffusivity, Oxide solubility, Allotropic
transformation, Recrystallization etc. Therefore, temperature must be controlled
to promote or avoid these factors as desired.

Generally, increasing temperature shortens diffusion welding cycle and

improves the economics of the process.

Diffusion welding temperature usually ranges from 0.55 to 0.8 times the
melting point of the base metal.

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3. TIME

Time is a dependent process parameter.

An increase in temperature shortens the time required to complete the diffusion

welding.

Time required for diffusion welding varies from a few minutes to several hours.

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4. SURFACE PREPARATION

Better prepared and cleaned surfaces lower the minimum diffusion welding
temperature or pressure.

Surfaces to be diffusion bonded are Machined, ground or abraded so that they

are sufficiently smooth to ensure that the interfaces can be pressed to proper
contact without excessive deformation.

Surfaces should be cleaned of chemically combined films, oxides, etc.

Surfaces should be cleaned of gaseous, aqueous or organic surface films.

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5. METALLURGICAL FACTORS

Metallurgical factors include Allotropic transformation, Recrystallization,

Surface oxides.

Hardenable steels undergo allotropic transformations and involve volume

change during diffusion welding. This may affect dimensional stability of the
welded component.

Many cold worked metals tend to recrystallize during diffusion welding which
may be good for certain materials but undesirable for others, e.g., refractory
metals which, when recrystallized, exhibit a much higher ductile to brittle
transition temperature).

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5. METALLURGICAL FACTORS

Beryllium, aluminium, chromium, etc., form tenacious surface oxides. So alloys

containing them are, therefore, more difficult to weld than those which form
less stable oxide films such as copper, nickel etc.

Metals that form tenacious oxide films require more elaborate pre-weld surface
preparation.

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6. USE OF INTERLAYERS

An interlayer is a lower strength intermediate or one containing a diffusive

element which solves alloying compatibility problems when joining dissimilar
metals.

Also, being soft, confines deformation to itself and thus minimizes distortion of
workpieces when pressed to contact.

Interlayers may, however, give rise to decreased strength or stability.

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PURPOSE OF INTERLAYERS
Interlayers are used serves the following purpose:

5. Interlayers promote melting at the interface similar to brazing

Commonly used Interlayer Materials are:

1. Thin Copper interlayers during diffusion welding of titanium alloys or
zirconium alloys.
2. Boron interlayer is used for diffusion welding of Ni alloys.
3. Titanium
4. Silver
5. Nickel

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ADVANTAGES OF DIFFUSION BONDING

Continuous, leak tight welds can be formed.

The process is well suited for dissimilar materials and ceramics.

Weldability is largely independent of material thickness.

Welds having the same physical, chemical and mechanical properties as the
base metal can be produced.

Heat treating operations can be incorporated during bonding cycle.

Numerous welds can be made simoltaneously.

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LIMITATIONS OF DIFFUSION BONDING

Diffusion welding is not classified as a mass production process

With dissimilar materials, difficulties due to time/temperature/pressure

requirements are frequently encountered

Diffusion welding requires a relatively long time consuming thermal cycle

Opposing surface must be mated in size to within a few angstroms of each

other in order to achieve a satisfactory metal bond

Difference in thermal expansion of members may need special attention

Limited non-destructive inspection methods available

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APPLICATIONS OF DIFFUSION
BONDING

Fabrications of reactor components in atomic energy industries.

Fabrication of honeycomb, rocket engines, helicopter rotor hub, turbine

components etc. in aerospace missile and rocketry industries (B1 Bomber &
Space shuttle)

Fabrication of composite materials.

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DIFFUSION BONDING OF AIRCRAFT

STRUCTURE

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DEFORMATION RESISTANCE
WELDING (DRW)

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DRW
It a new welding technique developed by Delphi Technologies.
Deformation Resistance Welding (DRW) is a process that employs resistance
heating to raise the temperature of the materials being welded to the appropriate
forging range followed by shear deformation which increases the contacting
surface area of the materials being welded.
It applies the heat and force of resistance welding to generate heat, with tooling
designed to create the necessary deformation.
This process is easily automated and creates near instantaneous, leak proof joints
with uniform circumferential strength capable of holding fluids and gases.

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 The connection is formed by the solidification of the molten metal where the
members meet.
DRW employs equipments similar to diffusion welding (auotoclaves or presses).
Usually it employs hydraulic or mechanical presses for applying pressure
It creates a better and thermal distortion free thin metal weld joints compared to
the application of TIG or brazing.

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JOINT DESIGN FOR DRW

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MATERIALS WELDED USING DRW

Low Carbon Steels

High Speed Steel Bits

Coated Steels

Al-Mg , Al-Mn alloys

Nickel Alloys

Monel Metal

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ADVANTAGES OF DRW

Effective for thin tubular components .

Easily applied to broad range of steel alloys including AHSS.

Rapid production rates and easily automated.

Process monitoring for quality is applicable.

Provides the ability to join different types of metals with solid state bonds in a
variety of configurations including Tube-to-sheet, Tube-to-tube and Tube-tosolid.

Costly stampings and adhesives can be eliminated

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ADVANTAGES OF DRW

No filler material required

Lowers materials and capital cost

Reduces welding cycle time and cost in manufacturing an array of structures

built with hollow members

Enhanced design flexibility enabling new structural approaches

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APPLICATIONS OF DRW

Heat exchangers

Load-bearing structural applications like bridges

Water heaters

Computer cooling systems

Frames in motorcycles, recreational vehicles, bicycles, wheelchairs etc

Chassis/suspension

Chassis module assemblies

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A deformation resistance welded pipe joints. 41