Metal diffusion bonding is an essential joining method for achieving a high-purity interface when two similar metals require superior structural integrity. The process involves applying high temperature, and pressure to metals mated together in a hot press causes the atoms on solid metallic surfaces to intersperse and bond.

Specialized furnaces with integrated presses provide superior control of pressure and temperature to create better diffusion bonds when joining similar or dissimilar metals.

Solar Manufacturing successfully completed the installation and start-up of a large 100-ton-force vacuum hot press at Refrac Systems’ commercial and aerospace diffusion bonding operation in Chandler, Ariz. The press includes a 2-bar-gas fan-quench cooling system. The furnace hot zone was modified to contain a 100-ton-load hydraulic ram centered over the zone, which is configured to diffusion bond parts up to 36 inches wide x 48 inches long x 30 inches tall.

As a result of having minimal impurity content, even in the case of highly reactive metals, diffusion bonding has found significant application for the fabrication of complex titanium-alloy components.

The Doctor has always been intrigued by the innovation and design capability of engineers. Nowhere is this better illustrated than in equipment used for diffusion-bonding applications.

One of the many vacuum processes to take note of today is that of diffusion bonding (aka diffusion welding or thermo-compression bonding). This technology, although highly specialized, continues to gain in popularity with design engineers and is finding more applications throughout manufacturing. Let’s learn more.

Refrac Systems of Chandler, Ariz., contracted Solar Manufacturing to design and build a large 100-ton-load gas fan quench vacuum hot press (GFQVHP) system for its aerospace diffusion bonding operation.