Process Technology for Diffusion Welding with Cyclically Pulsative Joining Forces
<p>Schematic representation of a diffusion welding system (<b>a</b>) and the course of temperature and applied pressure over the process time (<b>b</b>) [<a href="#B1-metals-13-00547" class="html-bibr">1</a>].</p> "> Figure 2
<p>Possible design of a diffusion welding chamber—(<b>a</b>) a combination of a vacuum chamber with pressing plungers that realise the forces that were needed; (<b>b</b>) the charging feet allow the position-ing of the weld sample [<a href="#B10-metals-13-00547" class="html-bibr">10</a>]. Legend: pressing device (1); corresponding pressing plungers (2); charging feet (3); vacuum pump (4).</p> "> Figure 3
<p>Constructive implementation of the recipient. (<b>a</b>): Overall view of the construction including specific external parts; (<b>b</b>): components inside the vacuum chamber; (<b>c</b>): final production-technical implementation of the recipient. Legend: access to the process chamber incl. sight glass (1), connection valve for vacuum generation (2), cooling system (3), supports for positioning the recipient in the testing machine Power Swing MOT 100 kN Newline (4), additional shop windows (5), connecting elements for power transmission between the two systems (6), cooled connecting rod feedthrough incl. elastomer seal (7), lower ram platform (8), component to be joined (9), inductor (10), upper ram platform (11), inductor feedthrough (12), thermal shield (13).</p> "> Figure 4
<p>(<b>a</b>) Constructive implementation of the elastomer seal. Connection for the coolant supply (1), elastomer seals in triple design (2), holes for cooling (3); (<b>b</b>) implemented implementation incl. interface to the Power Swing system.</p> "> Figure 5
<p>Integration of the coil into the recipient—(<b>a</b>) look inside; (<b>b</b>) the coil photographed from different directions; (<b>c</b>) passage of the coil into the recipient.</p> "> Figure 6
<p>Constructive (<b>a</b>) and final (<b>b</b>) integration of the distance encoder, a capacitive sensor (measuring range: 0.2 mm; dyna. resolution 4 nm).</p> "> Figure 7
<p>Investigation of the effect of heat development/propagation over time in the recipient as a result of inductive component heating.</p> "> Figure 8
<p>(<b>a</b>) Sample height unsanded compared before/after. (<b>b</b>) Sample height compared before/after sanded samples, Ra = 0.2 µm, both processed in the <span class="html-small-caps">PVA Löt-und Werkstofftechnik GmbH</span> plant.</p> "> Figure 9
<p>Transverse micrographs of the joining zone during diffusion bonding of 1.0503 + 1.0503 processed in the <span class="html-small-caps">PVA Löt-und Werkstofftechnik GmbH </span>plant—<span class="html-italic">T</span><sub>weld</sub> = 900 °C, <span class="html-italic">F</span><sub>weld</sub> = 12.5 kN (≙ surface pressure of 10 N/mm<sup>2</sup>), process time: <span class="html-italic">t</span><sub>weld</sub> = 20 min (<b>a</b>), <span class="html-italic">t</span><sub>weld</sub> = 40 min (<b>b</b>), <span class="html-italic">t</span><sub>weld</sub> = 60 min (<b>c</b>).</p> "> Figure 10
<p>Transverse micrographs of the joining zone during diffusion bonding of 1.0503 + 1.0503 processed in the <span class="html-small-caps">SincoTec Test Systems GmbH</span> plant—<span class="html-italic">T</span><sub>weld</sub> = 900 °C, <span class="html-italic">F</span><sub>weld</sub> = 7 kN (≙ surface pressure of 10 N/mm<sup>2</sup>), vibration amplitude 1.5 kN, load change: 31,500, process time: <span class="html-italic">t</span><sub>weld</sub> = 10 min, micrograph position: left (<b>a</b>) and right (<b>c</b>) edge or centre of the specimen (<b>b</b>).</p> "> Figure 11
<p>Example of recorded parameters (mean load (<b>a</b>); vibration frequency (<b>b</b>); upsetting path (<b>c</b>)) during diffusion bonding of a 1.7227 + 1.0503 joint, surface untreated; <span class="html-italic">T</span><sub>weld</sub> = 900 °C, <span class="html-italic">F</span><sub>weld</sub> = 7 kN (≙ surface pressure of 10 N/mm<sup>2</sup>), vibration amplitude 1.5 kN, load change: 63,051, process time: <span class="html-italic">t</span><sub>weld</sub> = 20 min—the red line shows a correlation between the applied centre load, the vibration frequency and the upsetting path.</p> ">
Abstract
:1. Introduction
2. State of the Art
2.1. Fundamentals of Diffusion Welding
2.2. Recipient Design
2.3. Conclusions from the State of the Art and Objectives
- Reduction of the machining effort of joining the surfaces in advance.
- 2.
- Reduction of the welding time up to the replacement of the welding time by a frequency-based test criterion.
- 3.
- Adjustment of more favourable material properties through the frequency-superimposed application of force, and reduction of the phase thicknesses.
- Testing of materials and compounds in reactive environments through inert atmosphere or vacuum;
- Material and component testing under operating conditions, including temperature up to approx. 1000 °C, mechanical load in the compression and tensile range (static and dynamic), various inert ambient media;
- Reduction of the required measures for joining surface preparation by facilitated approximation of the surfaces to each other on an atomic level;
- Joining of materials in the pressure threshold range (welding pressure) up to 100 kN at characteristic frequencies up to 150 Hz and a variable number of load cycles;
- Enhancement of the factor frequency shift or frequency monitoring for non-destructive characterisation of the welded joint during the joining process and qualification of a joining time adapted to the process condition.
3. Experimental Methods
3.1. Concept of Technical Implementation
3.2. Construction
3.2.1. Vacuum Chamber—The Recipient
3.2.2. Sample Heating System
3.2.3. Control of the System
- With and without heating;
- Under vacuum or inert gas atmosphere;
- According to the type of pressure control (force- or distance-controlled).
4. Results—Benchmarking Samples
5. Conclusions
Author Contributions
Funding
Data Availability Statement
Acknowledgments
Conflicts of Interest
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Description 0 = 1 = | Heating without with | Atmosphere Vacuum Shield Gas | Pressure Control Strength-Regulated Travel-Regulated |
---|---|---|---|
scenario A 1 scenario A 2 | 1 | 0 | 0 |
1 | 0 | 1 | |
scenario B 1 scenario B 2 | 0 | 0 | 0 |
0 | 0 | 1 | |
scenario C 1 scenario C 2 | 1 | 1 | 0 |
1 | 1 | 1 | |
scenario D 1 scenario D 2 | 0 | 1 | 0 |
0 | 1 | 1 |
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John, B.; Letsch, H.; Wölck, J.; Hess, M.; Hensel, J. Process Technology for Diffusion Welding with Cyclically Pulsative Joining Forces. Metals 2023, 13, 547. https://doi.org/10.3390/met13030547
John B, Letsch H, Wölck J, Hess M, Hensel J. Process Technology for Diffusion Welding with Cyclically Pulsative Joining Forces. Metals. 2023; 13(3):547. https://doi.org/10.3390/met13030547
Chicago/Turabian StyleJohn, Björn, Holger Letsch, Johannes Wölck, Marcel Hess, and Jonas Hensel. 2023. "Process Technology for Diffusion Welding with Cyclically Pulsative Joining Forces" Metals 13, no. 3: 547. https://doi.org/10.3390/met13030547