Diffusion welding

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1 Operation definition
2 Schematic showing tool/work material interaction.
3 Typical part geometry (sheet, bar, tube, castings, machined parts, etc.)
4 Typical work materials (ferrous, non-ferrous, polymers, ceramics, etc.)
5 Process Considerations
6 How this value-adding operation helps achieve workpiece function.
7 References

[edit] Operation definition

Diffusion welding (DFW) is a solid state welding process by which two dissimilar metals can be bond together. Diffusion involves the the migration of atoms across the joint. The two materials are pressed together at an elevated temperature usually between 50 and 70% of the melting point. The pressure is used to relieved the void that may occur do to the different surfaces.

[edit] Schematic showing tool/work material interaction.

Image:Diffusionpicture.jpg

[edit] Typical part geometry (sheet, bar, tube, castings, machined parts, etc.)

Sheet metal stuctures are typical product of diffusion welding.

[edit] Typical work materials (ferrous, non-ferrous, polymers, ceramics, etc.)

This process is used primary to bind dissimilar metals and to bond reactive metals(titanium, beryllium, zirconium).

[edit] Process Considerations

DFW is used for fabrication complex parts in low quantities for mainly aerospace, nuclear, and electronics industries. The equipment cost is considerably high and is figured by the area that is being diffusion-bonded. Prices fall into the range of $3 to $6/mm^2 ($2000 to $4000/in^2).

[edit] How this value-adding operation helps achieve workpiece function.

In many military aircraft diffusion bonding will help to allow for the conservation of sxpensive stategic and the reduction of manufacturing costs. Some aircraft have over 100 diffusion-bonded parts, including; Fuselage frames, Outboard/Inboard actuator fittings, Main landing-gear trunnion, and Nacelle frame/support beams.