Aerospace & Defense Technology - August 2022 - 10

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Aerospace Alloys
The Science of
Joining Dissimilar Metals
in Aerospace Manufacturing
I
n aerospace, metal diffusion bonding is an essential joining method
for achieving a high-purity interface when two dissimilar metals
require superior structural integrity. The process involves
applying high temperature and pressure to metals mated together
in a hot press, causing the atoms on solid metallic surfaces to intersperse
and bond.
Today, there is no better commercially viable materials-joining process
than hot press diffusion bonding, because it can produce consistently
uniform results in a wide range of aerospace applications. The
applied pressure induced by hot-press equipment, combined with
software and loop-back sensors for precise control to within micrometer
accuracy, can produce constant pressure over several square feet
of area for component assembly. As a result, this technology has
attracted the interest of design engineers in the aerospace, semiconductor,
and energy industries.
With such a high degree of process control, the diffusion bonding
process is increasingly used to join dissimilar metals in aerospace.
Commercial processes of interest are titanium to iron-nickel alloys,
titanium alloys to stainless steel, and even some aluminum to metal
applications. The process also enables coupling between different
alloys in the same material group, such as mild steel, tool steel, and
metal-matrix composites.
To successfully use diffusion bonding in aerospace, an understanding
of the complexities of the interface and its effect on the chemical
and thermo-mechanical properties of the bond is required. However,
with the industry's traditional focus on welding and brazing, there has
been minimal formal education on diffusion bonding.
10
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Aerospace & Defense Technology - August 2022

Table of Contents for the Digital Edition of Aerospace & Defense Technology - August 2022

Aerospace & Defense Technology - August 2022 - Intro
Aerospace & Defense Technology - August 2022 - Sponsor
Aerospace & Defense Technology - August 2022 - Cov1
Aerospace & Defense Technology - August 2022 - Cov2
Aerospace & Defense Technology - August 2022 - 1
Aerospace & Defense Technology - August 2022 - 2
Aerospace & Defense Technology - August 2022 - 3
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Aerospace & Defense Technology - August 2022 - 64
Aerospace & Defense Technology - August 2022 - Cov3
Aerospace & Defense Technology - August 2022 - Cov4
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