Improved stochastic dissimilar diffusion bonding model with experimental validation

Abstract

Abstract. Diffusion bonding is a solid-state welding operation that has seen wide spread use in the aerospace industry, especially in combination with superplastic forming. It combines two relatively flat, clean surfaces at high temperature to create a near flawless weld over a large surface area. Modelling of diffusion bonding has been challenging due in part because of the larger variations in voids formed from the mating surfaces. This paper attempts to compensate for that inadequacy by implementing a stochastic diffusion bonding model based with theoretical voids formed from interacting surfaces. The model uses a statistical version of Pilling’s model in combination with surface roughness based initial conditions that estimates the possibilities of voids formed. The results of the model are compared with experimental results for three different alloys at a variety of process conditions along with presenting an investigation of the mechanics of the model for future improvements.