Diffusion Bonding Process Details

Diffusion Bonding Process Details

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Fundamentals of Diffusion Bonding Process

It is not just a technical article but a complete guide on the fundamentals of the diffusion bonding process. But, before we start, you must know the basics of the diffusion bonding process. In this guide, we will tell you everything you need to know about the process and its basics. So, keep reading!

diffusion bonding process


Diffusion bonding refers to the welding process of solid-state where no liquid or fusion phase is involved. In this process, the weld joints are welded with pure solid-state instead of the traditional method. You will notice plastic deformation at the surface of the interface. The environment plays an extremely important role in the diffusion bonding process. It helps in reducing the oxidation level. Moreover, the entire process takes place in an immobile environment.

The Basics of Diffusion Bonding

Basically, the process of welding solid-state is known as diffusion bonding. You can apply the process to both similar and dissimilar materials. You can even join the ceramic materials using the diffusion bonding process. The process involves the diffusion of atoms on the joint interface. The entire process of diffusion bonding takes place at an elevated temperature. The best part about the process is that it does not require any filler materials. Moreover, the joint process of similar materials is entirely autogenous as well. You can even use interlayers during the diffusion bonding of dissimilar materials.

Types of Diffusion Bonding

The types of diffusion bonding can be categorized into four basic types. No matter what the type is, all of them require a variety of thermal profiles. Let’s check out the types of diffusion bonding below.

  1. Solid-State Diffusion Bonding
  2. Activated Diffusion Bonding
  3. Liquid Interface Diffusion Bonding
  4. Transient Liquid Phase Diffusion Bonding

Diffusion Bonding Process – The Basic Principle

The basic principle of the process revolves around bonding. The principle is the movement of atoms or molecules from a region of higher concentration to the region of lower concentration. High pressure is applied on both the materials that are placed on each other. This helps in setting the process in motion. Moreover, the entire process of diffusion bonding is accelerated by heat. But, the important thing to remember here is that the heat temperature must not be too high. It should only range between 50 to 70% of the metal’s melting temperature.

Diffusion Bonding Process – The Details

Generally, the diffusion bonding process is applied to two or more materials that have almost the same structure as the crystalline. During the process, they clamp the workpieces together.  But, an important thing to note here is that both the metal surfaces need to face each other. It is extremely important for the successful completion of the project.

Once the materials are successfully clamped, the technicians apply heat and pressure on the workpieces for a lot of time. The surfaces are most commonly heated in a furnace. In some cases, the surfaces are also heated through electrical resistance. You can also use the hydraulic pressure to achieve the pressure that you require. As a result, you get the most accurate measure of the pressure.

Moreover, the surfaces of the bonded material are extremely important as well. You need to machine the metal surfaces for them to be as smooth as possible. Not only this, but the surfaces should also be kept free from chemical impurities and residues. You must also remove the material found between the workpieces. This will ensure the successful completion of the process.

If you are using the metals with strong oxide layers, you must carry out the process in an inert environment or a vacuum. This will ensure that the process is carried out successfully.

Diffusion Bonding Process – Summary

The entire diffusion bonding process can be summarized as follows.

1.      Preparation of the Welding Plate Surfaces

The first step involves the preparation of both the plate surfaces for welding. The basic requirement of the diffusion bonding process involves making the interface surfaces flat. This is what happens in this step. Both the interface surfaces are made equally flat. In addition to this, the interface surfaces are machined, cleaned, and polished as well. As a result, the chemical contaminants are removed from the surface. It is important because the presence of contaminant particles can reduce the level of diffusion between the welding plates.

2.      Clamping and Placing of the Plates

The next step involves the clamping and the placement of the plates over one another. This process takes place in an immobile environment or a vacuum chamber. The inert environment or the vacuum chamber is important because it helps prevent oxidation in the welding surfaces.

3.      Application of High Pressure and Temperature

The third step requires the start of the diffusion process. For this purpose, high temperature and pressure are applied to the assembled plates. An important thing to note here is that the temperature is applied on the plates with the help of furnace heating or electric heating. In addition to this, high pressure is applied to the assembled plates with the help of the hydraulic press. Some people also apply high pressure with the help of gas pressure or dead weight. This process requires a longer duration for proper diffusion. When the process starts, you will notice deformation at the interface of the surface. But, when diffusion takes place successfully, a proper interface boundary will be formed.

4.      Proper Diffusion of the Plates

Once the plates are properly diffused into each other, you will notice that a strong joint is formed. In addition to this, the interface boundary disappears as well leaving behind a clear joint. The joint that is formed through the process has the same properties as that of the base material.

diffusion bonding process


Final Words

That was your comprehensive guide on the diffusion bonding process and its basics. It is a highly useful process that offers a lot of advantages to both the users and the manufacturers. This is why it is gaining so much recognition these days.

Need more information on the diffusion bonding process? Contact us now and we will be happy to assist you.