Solid-State Joining of Dissimilar Single Crystal and Polycrystalline Ni-Based Superalloys Using Field-Assisted Sintering Technology

Lin, Charis; Singh, Jogender; Hogan, Matthew; Yamamoto, Namiko

doi:10.1007/s11661-024-07334-7

Cited by 2 publications

(1 citation statement)

References 36 publications

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“…FAST has been used recently in solid-state diffusion bonding as well [29]. FAST is promising since it can cover a wide range of applications and could potentially be used for joining of different superalloys, single crystals or polycrystalline crystal structures joining, high faying surface relative density, and localized melting zone free of vulnerable HAZ [30,31]. FAST thus has advantages over conventional technologies like Tungsten Inert Gas/Metal Inert Gas (TIG/MIG) welding that can cause cracking and elemental segregation if used on superalloys [32,33].…”

Section: Introductionmentioning

confidence: 99%

Solid-state diffusion bonding for INCONEl 617 superalloy using field-assisted sintering technology (FAST) guided by CALPHAD approach

Degnah,

Alnaser,

Kurdi

et al. 2024

Mater. Res. Express

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This study investigates solid-state diffusion bonding between two INCONEl 617 alloy samples using field-assisted sintering technology (FAST). The study focuses on analyzing the faying surface validating the theoretical alloy design modeling done by the CALculation of PHAse Diagrams (CALPHAD) approach followed by experimental validation. Varying kinetics’ limitations enabled phase stability and phase control governed by the CALPHAD approach alloy design. The alloy design contains a pseudo-binary phase diagram assisted with thermal mapping of a property phase diagram to obtain the optimum temperature of solid-state diffusion bonding while understanding phase fields and their evolution through Mo-increasing content and temperature increase. The FAST parameters recommended by CALPHAD were 800 °C under 10 MPa pressure with a holding time of 30 minutes. The investigation observations were promising where the faying surface contains γ only, while the further region on the alloy contains γ and γ`. It is worth mentioning that FAST advantage resulted in fine faying surface thickness of around 10 µm and a controlled heat affected zone (HAZ) leading to extreme reduction in recrystallization zone yielding an average grain size of 60-100 µm before and after diffusion bonding. Furthermore, two modes of metal carbide (MC) have been found, MC formed under the faying surface and micro-MC pools formed around the faying surface. 

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Section: Introductionmentioning

confidence: 99%

Solid-state diffusion bonding for INCONEl 617 superalloy using field-assisted sintering technology (FAST) guided by CALPHAD approach

Degnah,

Alnaser,

Kurdi

et al. 2024

Mater. Res. Express

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Flash Sintering of Bimetallic Assemblies for Turbine Disks in Next‐Generation Jet Engines

Saly,

Villechaise,

Sallot

et al. 2024

Adv Eng Mater

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René 77 and another advanced powder metallurgy nickel‐based superalloy are flash‐sintered and joined to produce a dual‐alloy assembly. This innovative process allows for the sintering of powders to achieve high relative densities or the formation of solid joints in a shorter time than is feasible with conventional diffusion bonding techniques. Examination of the microstructure after heat treatments reveals that diffusion and recrystallization phenomena can modulate the transition zone. The creep properties of both alloys, evaluated using stress relaxation tests, do not seem to differ by more than an order of magnitude, while the higher thermal stability of René 77 compared to Alloy B at 800 °C tips the scales. In tension, base materials show very high properties, while bimetallic specimens exhibit at least higher properties than René 77. However, failure occurs at the bond at high temperatures due to the formation of an oxide film during the bonding process. These encouraging results illustrate the potential and constraints of the flash‐sintering process for producing dissimilar assemblies, which may enhance the properties of next‐generation aero‐engine turbine disks.

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Solid-State Joining of Dissimilar Single Crystal and Polycrystalline Ni-Based Superalloys Using Field-Assisted Sintering Technology

Cited by 2 publications

References 36 publications

Solid-state diffusion bonding for INCONEl 617 superalloy using field-assisted sintering technology (FAST) guided by CALPHAD approach

Solid-state diffusion bonding for INCONEl 617 superalloy using field-assisted sintering technology (FAST) guided by CALPHAD approach

Flash Sintering of Bimetallic Assemblies for Turbine Disks in Next‐Generation Jet Engines

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