Diffusion Bonding of Titanium To 304 Stainless Steel: M. Ghosh, K. Bhanumurthy, G.B. Kale, J. Krishnan, S. Chatterjee

Diffusion bonding of titanium to
304 stainless steel

M. Ghosh , K. Bhanumurthy , G.B. Kale , J. Krishnan , S.
Chatterjee
Diffusion Bonding Technology of a

Titanium Alloy to a Stainless Steel
Web with an Ni Interlayer
Peng He, Jiuhai Zhang, Ronglin Zhou and Xiaoqiang Li
Diffusion bonding of titanium to 304 stainless steel
M. Ghosh , K. Bhanumurthy , G.B. Kale , J. Krishnan , S. Chatterjee
Why Ti-SS ?
The joints between Ti and SS find the wide application in Chemical processing, aero
space and Nuclear Industry
Why Diffusion bonding of Ti-SS?
1. The conventional fusion welding of these two materials results in segregation of

chemical species, stress concentration sites and formation of intermetallics at
interfaces as Ti and Fe are not completely soluble in solid state and form Fe2Ti and
FeTi intermetallic phases.
2. All these deleterious effects ultimately lead to premature failure of components in

service condition.
3. While Diffusion reaction between Ti/SS leads to the formation of Fe, Cr and Ni
based intermetallic compound.
Specimen Preparation
Materials: Commercially Pure Ti and 304 Stainless steel
Two types of geometries

Rectangular : 10105 mm Metallurgical Analysis
Cylindrical : 15mm and 30mm length Mechanical Testing
The mating surfaces of the rectangular and cylindrical

specimens are metallographically polished to a 1m
diamond finish and cleaned in acetone.
Building Diffusion Setup
The Diffusion bonding setup was built indigenously consisted of 5000N load
cell, Inconel plunger, Inconel sample supporting die, Stainless steel frame with
top and intermediate guide plate
Cylindrical furnace split type max operating temperature 1000C. Constant
temperature zone of 50mm was used for bonding specimen. Chromel-Alumel
thermocouple was inserted placed close to bond line.
The setup was kept in vacuum chamber operated by vacuum diffusion pump
coupled with single stage rotary pump.
Experimental Procedure
The polished mating faces of Ti and SS have kept in contact and

loaded in diffusion bonding setup.
The entire assembly was kept in a vacuum chamber with 10-4 mbar
vacuum-maintained throughout the bonding cycle.
The couples have been diffusion bonded at 850C, 900C and
950C for 2h under uniaxial pressure of 3MPa.
Heating rate for bonding cycle was 14C/min.
After the bonding the whole assembly was cooled in vacuum
chamber.
Experimental Procedure
Rectangular Specimen Cylindrical Diffusion couple

The bonded samples were cut off The test pieces with 4mm and gauge
perpendicularly from the joint portion and length of 20mm machined from
polished to 1m diffusion couple, with the bonded
interface at the centre of the gauge
Microstructural features were examined by length
optical microscope.
The concentration profiles were examined by
EPMA operating at 15kV with a stabilized The room temperature tensile strength
beam current of 40nA. of the cylindrical joints was evaluated at
cross head speed of 0.00083mm/s
The reaction products formed at the joint
portion of diffusion bonded couple were
characterized by X-ray diffractometer at an
operating voltage of 30kV and current of
20mA, copper target was used with the
scanning span of 20-70 with a step of
0.02/sec(=2).
Result and Discussion- Metallographic

Four distinct regions are observed on the micrographs
Parent stainless steel with annealing twins.
Heavily etched band presumably intermetallic
compound
Retained -Ti solid solution containing Fe, Cr and
Ni
Parent Ti with fine needles
There is substantial increase in width of diffusion

zone with the increase in bonding temperature.
Result and Discussion- Metallographic
The BSE of the couple bonded at 950C

clearly shows the formation of -phase near
stainless steel of width 20m
The phase adjacent to phase marked 1,2
and 3 where
1 Fe2Ti (Cr, Ni)
2 TiCr2+Fe2Ti(Cr)
3 Fe Ti(Cr, Ni)
The composition of phase doesnot change
significantly with increasing temperature
Result and Discussion- Concentration Profile
Concentration profiles for the specimen

bonded at 850C and 950C for 2h.
The concentration profile suggest that Fe and

Ni diffuse in Ti to large extent compare to Cr
Immobility of Cr might have led to the

formation phase.
Result and Discussion- Temperature dependence of layer growth

The temperature dependence of the individual phase width (X) can be represented
assuming the growth of each phase to be parabolic by equation
1
= 0 m/s2

Where K = 0 = inter diffusion rate constant
t = time of diffusion annealing in seconds
Qp= activation energy for larger growth in kJ/mol
n = 2 assumed for the parabolic growth of the individual phases
Based on the linear plot of lnX v/s 1/T the values of Qp and K0 are estimated for phase,
Fe2Ti and FeTi.
The activation energy values for these phases are found to be 184.3, 125.8 and 124.9
kJ/mol respectively.
Result and Discussion- Mechanical Properties
The highest strength values of 222MPa with adequate ductility was obtained
for a sample bonded at 850C and the bonding strength decreases with
increase of temperature.
Conclusion
Diffusion bonding of CP-Ti to 304 SS has been achieved using indigenously designed
and fabricated press.
The diffusion zone indicated the formation of , Fe2Ti and FeTi phases in the
diffusion zone and the activation energy values for these phases are found to be
184.3, 125.8 and 124.9 kJ/mol respectively.
The diffusion path evaluated on the basis of the concentration profiles of the main
diffusing elements could be correlated with the FeCrTi ternary isotherm at 950C.
Tensile testing of the diffusion bonded specimen at 850C indicated a bond strength
of 222 MPa with adequate ductility of 9%.
The bond strength decreases with increase in the bonding temperature and this is
essentially due to the increase in the width of the brittle intermetallic compounds.
Diffusion Bonding Technology of a Titanium Alloy to a Stainless Steel
Why Interlayer?
1. Direct bonding of Ti alloy to SS results in the formation of intermetallic
components like TiFe and TiFe2 in the bonded region. Because of less
solubility of Ti in Fe.
2. TiC is also formed because Ti is strong carbide formatting element
3. The formation of these elements not only results in brittleness of the
joints, it induces large internal stresses
4. The difference in linear expansion and heat transmission coefficient
between Ti alloy and steel which leads to crack.
Why Ni ?
1. Ni has good erosion resistance and form unlimited solid solution with Fe
2. Ni-Ti metallic compounds has certain plasticity.
Materials:
Ti alloy: 1430mm
SS as a web: 6m mesh
Ni foil(Interlayer): 30m
Experiment Procedure:
Diffusion bonding experiment was conducted in vacuum of 310-4 Pa
The primary diffusion bonding parameters (temperature, pressure and time) are
varied from lower to higher value to analyze their effect on shear strength of the
bonded joint.
Test:
Shear Test
Fracture Analysis
EPMA- the dispersion of elements in diffusion layer and in metallic compounds
Effect of Temperature on Strength
At 750C the shear strength is 42MPa(very low).

Because yield stress of the bonded material is still
high,
Contact of the bonded surface is poorer, thermal
excitation is not enough, specimen fracture occurs
on the interface of Ni-SS.
With the increasing temperature, the yield stress of
the master alloy decreases and the atomic
diffusivity increases, the deposition rate and the
shear strength of the bond joint increases.
At the temperature of 850C the shear strength of
the bond joint is maximum(147MPa), Specimen
fractured at Ni-Ti Interface.
With further increase of the bond temperature their
only a less change in shear strength of the bond and
fracture occurred at Ni-Ti Interface.
NiTi metallic compound increases rapidly when
bond temperature reaches 910C
Effect of Bond Specific Stress on the strength

of the bond joint
When P 10MPa: with the increase of P the shear

strength increases rapidly
When P is small contacts are established in
microprotuberance of the bond surface (not in pit), so
the deposition rate and the shear strength of the
lower, contact rates are lower and fracture occurs on
the interface of Ni-SS
When P10MPa: the influence of P on the shear
strength reduces.
With the increases of P, a small change in deposition
rate occurs, contact rates are higher and fracture
occurs mostly on SS web
Effect of bond time on the shear

strength of the bond joint
When t is 5-10min, the shear strength increases

rapidly
When t is 10-15min, the shear strength
changes a little
When t is more than 15mins, the thickness NiTi
metallic compound increases remarkably and
shear strength of the joint decreases
Dispersion of the element and the microstructure

in diffusion layer
Dispersion of the element and the microstructure in diffusion layer
Certain amount of diffusion occurs between Ni and master alloy, in mutual diffusion
layer composition changes gradually near interface.
The diffusion distance from Ni to stainless steel web is short.
Diffusion layer widens with an increase of temperature.
No transition layer was found on the Ni and SS web, but a wider transition layer and
bright strip was observed between Ni and Ti alloy.
The relationship between deformation quantity of Ti alloy and bond

specific strength
During diffusion bonding, corrugation deformation
occurs in SS webs, because of coefficient of linear
expansion of the SS web is higher Ti alloy, which
seriously affect the precision of the specimen.
Remedy: After the temperature is upto the bond
temperature, keep that temperature for 5mins
then exert the bond specific stress.
But after bonding. If the SS web still has small
corrugation deformation, it can be analyzed that
the plastic deformation of Ti alloy under high
temperature extrude the SS web which bring
corrugation deformation in SS. Hence it is
necessary to control the deformation of Ti alloy.
Conclusion
The good joint between the interlayer metal Ni and the stainless steel web has
been obtained, but the transition layer is formed between the Ni and Ti alloy
Under high temperature several fragile layers such as TiNi3, TiNi, and Ti2Ni
come into being on the Ti/Ni interface, and layers are thick
Under low temperature a single TiNi layer is formed, and joints are weak.
Optimum bonding parameters are T=850-880C, P= 8-10MPa, t =10-20min

Shear strength = 60-74 MPa.

Diffusion Bonding of Titanium To 304 Stainless Steel: M. Ghosh, K. Bhanumurthy, G.B. Kale, J. Krishnan, S. Chatterjee

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Diffusion bonding of titanium to

304 stainless steel

Diffusion Bonding Technology of a

Why Diffusion bonding of Ti-SS?

1. The conventional fusion welding of these two materials results in segregation of

2. All these deleterious effects ultimately lead to premature failure of components in

Materials: Commercially Pure Ti and 304 Stainless steel

Two types of geometries

The mating surfaces of the rectangular and cylindrical

Building Diffusion Setup

The polished mating faces of Ti and SS have kept in contact and

Rectangular Specimen Cylindrical Diffusion couple

Result and Discussion- Metallographic

There is substantial increase in width of diffusion

Result and Discussion- Metallographic

The BSE of the couple bonded at 950C

Result and Discussion- Concentration Profile

Concentration profiles for the specimen

The concentration profile suggest that Fe and

Immobility of Cr might have led to the

Result and Discussion- Temperature dependence of layer growth

Result and Discussion- Mechanical Properties

Effect of Temperature on Strength

At 750C the shear strength is 42MPa(very low).

Effect of Bond Specific Stress on the strength

When P 10MPa: with the increase of P the shear

Effect of bond time on the shear

When t is 5-10min, the shear strength increases

Dispersion of the element and the microstructure

Dispersion of the element and the microstructure in diffusion layer

The relationship between deformation quantity of Ti alloy and bond

Optimum bonding parameters are T=850-880C, P= 8-10MPa, t =10-20min

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