Diffusion bonding mesh is one of the techniques for connecting parts by applying pressure to them. It carries out in a vacuum at high temperature by applying compressive forces to the parts.
This method of bonding under pressure differs from others in that the process occurs when exposed to high temperatures, 0.5-0.7 Tm, and low specific compressive pressures, 0.5-0 MPa. In this case, isothermal exposure can be either several minutes or several hours.
The cleaning of the bonded surfaces from oxides. The occurrence of creep at high temperatures, and recrystallization.
This type of bonding can carry out according to two technological schemes that differ from each other in the nature of the load application. One technology involves the use of a constant load, the magnitude of which does not reach the yield strength.
The processes that occur in the joined materials in this case are similar to creep. This method of diffusion bonding is the so-called free deformation. It is the simplest, and therefore in practice it is widely common.
Another technology involves the use of a special device that moves at a certain speed during Diffusion bonding mesh and provides a load with subsequent plastic deformation. The stresses in this case exceed the yield strength. This method is called diffusion bonding with forced deformation.
Diffusion bonding has found wide application in industry, in particular, it is indispensable in the field of electronic instrumentation. It allows you to create metal-ceramic and cathode assemblies, vacuum-tight connections from various materials, semiconductor devices, etc.
This method of bonding is ideal when working with parts of large sizes and complex shapes, which are impossible or uneconomical to manufacture using conventional machining and pressure forming. Especially if it is a pilot or small-scale production.
Due to the combination of Diffusion bonding mesh with shaping in the superplastic mode, it is possible to obtain multilayer hollow structures: ribs, corrugations, honeycombs, etc.
Thanks to diffusion bonding, it is possible to weld:
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Advantages:
Disadvantages:
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Diffusion bonding using intermediate consumable or non-consumable spacers (layers). On the surface of the parts to join, special sublayers apply. This is necessary in order to:
Table of bonding temperatures
In most cases, copper, nickel, gold or silver are common for gaskets. Their thickness is within 2-7 microns. To prevent the occurrence of unwanted phases, a thicker material - foil - can be common as a barrier gasket.
The choice of material for the sublayer bases on the fact that its diffusion coefficient into the base material exceeded the diffusion coefficient of the base material into the sublayer.
If parts made of glass or ceramics are to weld, then the metal sublayer heats so that it oxidizes and its Diffusion bonding mesh into the material of the part is easier.
To connect quartz glass and copper, a copper layer applies to the glass, which is subject to oxidation under the influence of a temperature of 800 ° C for 3-5 minutes.
Diffusion bonding with impact loading in a vacuum is common in cases where there is a possibility of intermetallic formation at the weld site.
With this method, the contact zones of the parts locally heat, after which they affect by a single force impulse, the speed of which is 1-30 m/s. As a result, when a dynamic load applies, plastic deformation occurs in the materials to join at the point of their contact and a welded joint appears.
Sometimes compression of parts achieves using special devices that cover workpieces made of materials with different coefficients of linear expansion. The compression of the material carries out due to the pressure difference in vacuum and the external gaseous medium.
With this method, the contact zones of the parts locally heat, after which they affect by a single force impulse, the speed of which is 1-30 m/s. As a result, when a dynamic load applies, plastic deformation occurs in the materials to join at the point of their contact and a welded joint appears. This happens in 1-10ms.
In the image above, you have read all the basic information. We offer you to get acquainted with the technology of Diffusion bonding mesh in more detail. After all, diffusion bonding in a vacuum allows you to get a truly high-quality joint without the use of classical bonding technologies.
It all starts with a special chamber in which the parts place. A technical vacuum creates in the chamber, while the vacuum in the chamber should be as high as possible. This will give you the best bonding results.
