Enhanced diffusion bonding of alloy 617 using electric field-assisted sintering

Zhang, Xinchang; McMurtrey, Michael D.; Bass, Ryann E.; Patterson, Tate; Mohale, Ninad; Lillo, Thomas M.; Rufner, Jorgen Fredrick

doi:10.1016/j.jmrt.2023.09.080

Title: Enhanced diffusion bonding of alloy 617 using electric field-assisted sintering

Journal Article · 14 September 2023 · Journal of Materials Research and Technology

DOI: https://doi.org/10.1016/j.jmrt.2023.09.080 · OSTI ID:2205213

Zhang, Xinchang ^[1]; McMurtrey, Michael D. ^[1];

^[1];

^[1]; Mohale, Ninad ^[1]; Lillo, Thomas M. ^[1];

^[1]

Idaho National Laboratory (INL), Idaho Falls, ID (United States)

The development of compact heat exchangers (CHXs) has gained increasing interest in many industries owing to their high thermal efficiency and reduced size. Diffusion bonding (DB) is an advantageous technique for fabricating CHXs. Alloy 617 is a candidate for manufacturing CHXs for high-temperature advanced nuclear reactors due to its elevated-temperature properties. Previous endeavors in DB of Alloy 617 were conducted by hot pressing (HP), which reported precipitates at the diffusion-bond interface, limited grain boundary (GB) migration, and significantly reduced high-temperature mechanical properties. To overcome these challenges, this study investigated DB of Alloy 617 using electric field-assisted sintering (EFAS). Stacks composed of three sheets were bonded with EFAS using different temperatures, pressures, and hold times. DB using HP as the zero-current analog of EFAS was also performed for comparison. The result shows that Cr- and Mo-rich precipitates were formed at the interface of the hot-pressed samples. The electric current and temperature in EFAS play a significant role in precipitation and GB migration. The electric current coupled with correct temperatures can effectively prevent precipitate formation at the interface and achieve excellent GB migration. Nanoscale Al-rich oxide was formed at the interface of the samples made by both HP and EFAS, but grain boundaries can ignore the nanoscale Al-oxide and migrate across the interface. The temperature, pressure, and hold time also affected diffusion. The temperature is a prerequisite for a successful GB migration, and GB migration can be enhanced by increasing pressure and hold time.

View Accepted Manuscript (DOE)

Cite

Export

Save

Research Organization:: Idaho National Laboratory (INL), Idaho Falls, ID (United States)

Sponsoring Organization:: USDOE

Grant/Contract Number:: AC07-05ID14517

OSTI ID:: 2205213

Report Number(s):: INL/JOU-22-67042-Revision-0; TRN: US2406897

Journal Information:: Journal of Materials Research and Technology, Vol. 26, Issue -; ISSN 2238-7854

Publisher:: Brazilian Metallurgical, Materials and Mining AssociationCopyright Statement

Country of Publication:: United States

Language:: English

References (39)

Enhanced atomic diffusion of Fe–Al diffusion couple during spark plasma sintering Li, Ruidi; Yuan, Tiechui; Liu, Xiaojun Scripta Materialia, Vol. 110 https://doi.org/10.1016/j.scriptamat.2015.08.012	journal	January 2016
Consolidation by electrical resistance sintering of Ti powder Montes, J. M.; Rodríguez, J. A.; Cuevas, F. G. Journal of Materials Science, Vol. 46, Issue 15 https://doi.org/10.1007/s10853-011-5456-1	journal	August 2011
Effect of thermal aging on microstructure, hardness, tensile and impact properties of Alloy 617 Narayan Singh, Aditya; Moitra, A.; Bhaskar, Pragna Materials Science and Engineering: A, Vol. 710 https://doi.org/10.1016/j.msea.2017.10.078	journal	January 2018
Fast recrystallization and phase transformation in ECAP deformed Ti–6Al–4V alloy induced by pulsed electric current Zhao, Zhiyong; Wang, Guofeng; Zhang, Yanling Journal of Alloys and Compounds, Vol. 786 https://doi.org/10.1016/j.jallcom.2019.01.328	journal	May 2019
Influence of electric current on interdiffusion kinetics of W-Ti system during spark plasma sintering Deng, Shenghua; Yuan, Tiechui; Li, Ruidi International Journal of Refractory Metals and Hard Materials, Vol. 75 https://doi.org/10.1016/j.ijrmhm.2018.04.014	journal	September 2018
Effect of spark plasma sintering temperature on the multi-scale microstructure evolution and mechanical properties of Ti2AlC/TiAl composites with network architecture Wang, Zhenbo; Liu, Pei; Wang, Aiqin Journal of Materials Research and Technology, Vol. 25 https://doi.org/10.1016/j.jmrt.2023.07.090	journal	July 2023
Time-dependent dielectric breakdown of surface oxides during electric-field-assisted sintering Bonifacio, Cecile S.; Holland, Troy B.; van Benthem, Klaus Acta Materialia, Vol. 63 https://doi.org/10.1016/j.actamat.2013.10.018	journal	January 2014
Electric current activated sintering (ECAS) of undoped and titanium-doped BiFeO3 bulk ceramics with homogeneous microstructure Bernardo, Mara S.; Jardiel, Teresa; Caballero, Amador C. Journal of the European Ceramic Society, Vol. 39, Issue 6 https://doi.org/10.1016/j.jeurceramsoc.2019.01.045	journal	June 2019
The effect of direct electric current on precipitation in a bulk Al-4 wt % Cu alloy Onodera, Yukio; Hirano, Ken -Ichi Journal of Materials Science, Vol. 11, Issue 5 https://doi.org/10.1007/BF00542295	journal	May 1976
Cracking behavior of AISI 316L stainless steel powder by gas nitriding and its influence on spark plasma sintering Lu, Jiping; Wang, Qingxiang; Liu, Chi Journal of Materials Research and Technology, Vol. 20 https://doi.org/10.1016/j.jmrt.2022.08.163	journal	September 2022
Nucleation and growth mechanism of crystalline phase for fabrication of ultrafine-grained Ti66Nb13Cu8Ni6.8Al6.2 composites by spark plasma sintering and crystallization of amorphous phase Li, Y. Y.; Yang, C.; Qu, S. G. Materials Science and Engineering: A, Vol. 528, Issue 1 https://doi.org/10.1016/j.msea.2010.09.037	journal	November 2010
Reaction diffusion rate coefficient derivation by isothermal heat treatment in spark plasma sintering system Yang, C.; Mo, D. G.; Lu, H. Z. Scripta Materialia, Vol. 134 https://doi.org/10.1016/j.scriptamat.2017.03.005	journal	June 2017
Electric current induced precipitation in maraging steel Kapoor, R.; Sunil, S.; Bharat Reddy, G. Scripta Materialia, Vol. 154 https://doi.org/10.1016/j.scriptamat.2018.05.013	journal	September 2018
Effect of sintering temperature on the microstructure and mechanical properties of Fe–30%Ni alloys produced by spark plasma sintering Shongwe, Mxolisi Brendon; Diouf, Saliou; Durowoju, Mondiu Olayinka Journal of Alloys and Compounds, Vol. 649 https://doi.org/10.1016/j.jallcom.2015.07.223	journal	November 2015
Effect of Direct Current on Precipitation in Quenched Al + 4% Cu Thin Films Shine, M. C.; Herd, S. R. Applied Physics Letters, Vol. 20, Issue 6 https://doi.org/10.1063/1.1654117	journal	March 1972
Joining of 316L stainless steel by using spark plasma sintering method Yang, Jinhua; Trapp, Johannes; Guo, Quangui Materials & Design (1980-2015), Vol. 52 https://doi.org/10.1016/j.matdes.2013.04.091	journal	December 2013
Diffusion bonding of nickel-based superalloy GH4099 with pure nickel interlayer Xiong, Jiangtao; Yuan, Lin; Zhu, Yuan Journal of Materials Science, Vol. 54, Issue 8 https://doi.org/10.1007/s10853-018-03274-x	journal	January 2019
Laser assisted diffusion bonding of TC4 titanium alloy to 301 stainless steel using a Ni interlayer Meng, Yu; Gu, Xiaoyan; Cui, Meng Journal of Materials Research and Technology, Vol. 21 https://doi.org/10.1016/j.jmrt.2022.09.065	journal	November 2022
Fabrication of highly compact Inconel 718 alloy by spark plasma sintering and solution treatment followed by aging Yan, Shuaijiang; Wang, Qingxiang; Chen, Xing Vacuum, Vol. 163 https://doi.org/10.1016/j.vacuum.2019.01.048	journal	May 2019
Effect of long-term service exposure on microstructure and mechanical properties of Alloy 617 Akbari-Garakani, Mohammad; Mehdizadeh, Mohsen Materials & Design, Vol. 32, Issue 5 https://doi.org/10.1016/j.matdes.2011.01.017	journal	May 2011
A review of multi-physical fields induced phenomena and effects in spark plasma sintering: Fundamentals and applications Hu, Zheng-Yang; Zhang, Zhao-Hui; Cheng, Xing-Wang Materials & Design, Vol. 191 https://doi.org/10.1016/j.matdes.2020.108662	journal	June 2020
Electromigration in ULSI interconnects Tan, Cher Ming; Roy, Arijit Materials Science and Engineering: R: Reports, Vol. 58, Issue 1-2 https://doi.org/10.1016/j.mser.2007.04.002	journal	October 2007
Effective atomic diffusion coefficient dependence on applied pressure during spark plasma sintering Li, X. X.; Yang, C.; Chen, T. Materialia, Vol. 6 https://doi.org/10.1016/j.mtla.2019.100334	journal	June 2019
Diffusion bonding of 410 stainless steel to copper using a nickel interlayer Sabetghadam, H.; Hanzaki, A. Zarei; Araee, A. Materials Characterization, Vol. 61, Issue 6 https://doi.org/10.1016/j.matchar.2010.03.006	journal	June 2010
High-temperature mechanical behaviors of diffusion-welded Alloy 617 Sah, Injin; Hwang, Jong-Bae; Kim, Woo-Gon Nuclear Engineering and Design, Vol. 364 https://doi.org/10.1016/j.nucengdes.2020.110617	journal	August 2020
Fabrication and design aspects of high-temperature compact diffusion bonded heat exchangers Mylavarapu, Sai K.; Sun, Xiaodong; Christensen, Richard N. Nuclear Engineering and Design, Vol. 249 https://doi.org/10.1016/j.nucengdes.2011.08.043	journal	August 2012
Effect of sintering pressure and temperature on structure and properties of Ni Al metal-intermetallic composites produced by SPS Ogneva, T. S.; Bataev, I. A.; Mali, V. I. Materials Characterization, Vol. 180 https://doi.org/10.1016/j.matchar.2021.111415	journal	October 2021
In situ transmission electron microscopy study of dielectric breakdown of surface oxides during electric field-assisted sintering of nickel nanoparticles Bonifacio, Cecile S.; Rufner, Jorgen F.; Holland, Troy B. Applied Physics Letters, Vol. 101, Issue 9 https://doi.org/10.1063/1.4749284	journal	August 2012
Diffusion bonding of copper alloy and nickel-based superalloy via hot isostatic pressing Xiao, Yi; Lang, Lihui; Xu, Wencai Journal of Materials Research and Technology, Vol. 19 https://doi.org/10.1016/j.jmrt.2022.05.152	journal	July 2022
Creep Behavior of Diffusion-Welded Alloy 617 Sah, Injin; Hwang, Jong-Bae; Kim, Eung-Seon Metals, Vol. 11, Issue 5 https://doi.org/10.3390/met11050830	journal	May 2021
Spark plasma assisted diffusion bonding of titanium and stainless steel: Role of pulse current in diffusion kinetics and microstructural evolution Ananthakumar, K.; Vivekanandhan, P.; Kumaran, S. Vacuum, Vol. 177 https://doi.org/10.1016/j.vacuum.2020.109394	journal	July 2020
Diffusion bonding of Ti-45Al-7Nb-0.3W alloy by spark plasma sintering Zhao, Kun; Liu, Yong; Huang, Lan Journal of Materials Processing Technology, Vol. 230 https://doi.org/10.1016/j.jmatprotec.2015.11.030	journal	April 2016
Effect of direct current patterns on densification and mechanical properties of binderless tungsten carbides fabricated by the spark plasma sintering system Tang, Wei; Zhang, Li; Zhu, Ji-fei International Journal of Refractory Metals and Hard Materials, Vol. 64 https://doi.org/10.1016/j.ijrmhm.2017.01.010	journal	April 2017
Effects of applied pressure on the densification rates in current-activated pressure-assisted densification (CAPAD) of nanocrystalline materials Alaniz, J. E.; Dupuy, A. D.; Kodera, Y. Scripta Materialia, Vol. 92 https://doi.org/10.1016/j.scriptamat.2014.07.015	journal	December 2014
The recovery of tensile ductility in diffusion-bonded Ni-base alloys by post-bond heat treatments Sah, Injin; Kim, Donghoon; Lee, Ho Jung Materials & Design, Vol. 47 https://doi.org/10.1016/j.matdes.2012.12.061	journal	May 2013
A study on diffusion bonding performance of inconel 617 heat exchanger Song, Chan Ho; Cho, Il Hwan; Choi, Jun Seok International Journal of Precision Engineering and Manufacturing, Vol. 16, Issue 5 https://doi.org/10.1007/s12541-015-0124-z	journal	May 2015
Effects of Pulse Current on an Aluminum Powder Oxide Layer During Pulse Current Pressure Sintering Nagae, Takekazu; Yokota, Masaru; Nose, Masateru MATERIALS TRANSACTIONS, Vol. 43, Issue 6 https://doi.org/10.2320/matertrans.43.1390	journal	January 2002
Direct current-enhanced densification kinetics during spark plasma sintering of tungsten powder Deng, Shenghua; Li, Ruidi; Yuan, Tiechui Scripta Materialia, Vol. 143 https://doi.org/10.1016/j.scriptamat.2017.09.009	journal	January 2018
Investigating microstructural evolution at the interface of friction stir weld and diffusion bond of Al and Mg alloys Mofid, M. A.; Loryaei, E. Journal of Materials Research and Technology, Vol. 8, Issue 5 https://doi.org/10.1016/j.jmrt.2019.06.049	journal	September 2019

Similar Records

Electric field enhanced diffusion welding of alloy 617: Microstructural characteristics and mechanical properties

Journal Article · 2024 · Materials Science and Engineering. A, Structural Materials: Properties, Microstructure and Processing · OSTI ID:2530539

Zhang, Xinchang; McMurtrey, Michael D.; Patterson, Tate; +1 more

Microstructure and mechanical performance of welded joint between a novel heat-resistant steel and Inconel 617 weld metal

Journal Article · 2018 · Materials Characterization · OSTI ID:22804985

Zhang, Yu; Jing, Hongyang; Xu, Lianyong; +3 more

Precipitate Redistribution during Creep of Alloy 617

Journal Article · 2009 · Metallurgical and materials Transactions A · OSTI ID:968691

Schlegel, S; Hopkins, S; Young, E; +3 more

Related Subjects

36 MATERIALS SCIENCE
diffusion welding
electric-field-assisted sintering
hot pressing
alloy 617
compact heat exchangers

Title: Enhanced diffusion bonding of alloy 617 using electric field-assisted sintering

Citation Formats

References (39)

Similar Records

Related Subjects