Diffusion Bonded Joint Welding with a Ductile Buffer Layer
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Solution Overview
Problem
The ductility of diffusion bonded joints decreases at high temperatures during fusion welding, leading to increased cracking sensitivity compared to the base metal parts, resulting in potential cracking due to strain caused by the welding process.
Innovation Solution
A welding method that involves forming a buffer layer with higher ductility than the diffusion bonded joints in the welding region, which absorbs and buffers the strain from fusion welding, thereby suppressing cracking. The buffer layer can be formed using various methods such as overlay welding, powder sintering, or ultrasonic welding, and the diffusion bonded structure is then fusion welded to another part from above the buffer layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If fusion welding is performed on a diffusion bonded structure, then the diffusion bonded structure can be bonded to another part, but the ductility of the diffusion bonded joint decreases at high temperature leading to increased cracking sensitivity
Solution Approach 1:
A buffer layer is introduced as an intermediary between the diffusion bonded joint and the fusion welding zone. This buffer layer has higher ductility than the diffusion bonded joint and absorbs the strain generated during fusion welding, preventing crack propagation into the diffusion bonded joint while still allowing the structure to be bonded to another part.
Solution Approach 2:
The buffer layer is formed in advance before the fusion welding process. By preparing the buffer layer beforehand in the welding region, the structure is pre-equipped with a strain-absorbing layer that will protect the diffusion bonded joint during the subsequent welding operation.
2Device complexity
If the diffusion bonded structure is welded directly without a buffer layer, then the manufacturing process is simpler, but strain from welding causes cracking in the diffusion bonded joint
Solution Approach 1:
The buffer layer serves as a mediator that is relatively simple to implement (可以通过 overlay welding 或其他常规工艺形成) but provides significant protection to the diffusion bonded joint, maintaining joint integrity without substantially complicating the overall manufacturing process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The buffer layer effectively absorbs and buffers the strain from fusion welding, reducing the likelihood of cracking in the diffusion bonded joints, even under high constraint conditions, and maintaining ductility at high temperatures.
Implementation Method 1
the buffer layer having higher ductility than the diffusion bonded joint... the buffer layer absorbs and buffers strain caused by the fusion welding
Implementation Method 2
the diffusion bonded structure formed by diffusion bonding metal parts to each other
Data Source
AI summary
A welding method of a diffusion bonded structure in which the diffusion bonded structure formed by diffusion bonding metal parts to each other is bonded to another part by fusion welding includes a buffer layer forming step of forming a buffer layer in a welding region including a diffusion bonded joint of the diffusion bonded structure, the buffer layer having greater ductility than the diffusion bonded joint, and a welding step of bonding the welding region in which the buffer layer is formed to the another part by performing the fusion welding from above the buffer layer.