Transient liquid phase (TLP) bonding
TLP bonding process
-
setting up the bond
-
heating to the specified bonding temperature to produce a liquid in the bond region
-
holding the assembly at the bonding temperature until the liquid has isothermally solidified due to diffusion
-
homogenizing the bond at a suitable heat-treating temperature.
-
evaporating an element out of the substrate material to create a “glazed” surface [113].
Nearest order | Freq. (%) | References |
---|---|---|
1 kPa | 8 | |
10 kPa | 5 | |
100 kPa | 16 | |
1 MPa | 36 | |
10 MPa | 31 | |
100 MPa | 4 |
TLP bonding kinetics
-
melting of the interlayer
-
dissolution of the substrate material
-
isothermal solidification
-
homogenization of the bond region.
Thickness range (μm) | Common thickness(es) (μm) | Freq. (%) | References |
---|---|---|---|
<1 | 5 | ||
1–5 | 1, 2 | 10 | |
10–30 | 20, 25 | 35 | |
40–60 | 50 | 24 | |
70–150 | 75, 100 | 18 | |
200–500 | 200, 500 | 6 | |
>500 | 2 |
Melting
Dissolution
Solidification
Homogenization
Time frame of TLP bonding
-
Heating to the bonding temperature, CP1–5a: less than a minute to about an hour; dependent on the method of heating, the heating rate of the heating apparatus, and the substrate material’s thermal properties
Critical interlayer thickness
Optimal bonding temperature
Modeling of TLP bonding
Advantages and disadvantages of TLP bonding
-
the process is highly tolerant to the presence of a faying surface oxide layer [2, 6, 7, 11, 13, 21, 42, 47, 48, 56, 67, 80, 93, 136, 147‐149, 186] and therefore requires less joint preparation and no fluxing agents [11, 18, 42, 173, 187]; in a few rare cases surface oxides are actually beneficial to the process [129]
Applications of TLP bonding
Substratea
| Interlayer(s)b
| Reference(s) | |
---|---|---|---|
Ni-based alloys
| |||
GTD-111 | MBF-30, MBF-50 | ||
Inconel 600 | NB 150 | [135] | |
Inconel 617 | BNi-3, BNi-6 | ||
Inconel 625 | BNi-2 | [104] | |
Inconel 713C | BNi-6 | [88] | |
Inconel 718 | BNi-2 | [104] | |
Inconel 738 | NB 30, NB 150, BNi-3, MBF-60, MBF-80, DF-3 | ||
Inconel MA758 | Ni–B, Ni–Cr–Si–Fe–B, MBF-80 | ||
Inconel MA760 | Ni–Cr–P, Ni–Cr–Si–Fe–B | [64] | |
Inconel 939 | F20, F24, F25, F26, F27, MBF-80 | [59] | |
Mar-M247 | F20, F24, F25, F26, F27, MBF-80 | [59] | |
Nimonic 80A | Ni|NB 125|Ni | [109] | |
René N5 | Ni–Ge, Ni–Mn, Ni–Mn–Si, D-15 | ||
Udimet 700 | Ni–Cr–Co–Mo–B | [14] | |
Waspaloy | NB 150 | ||
Ni–6.4Al | Ni–B | [157] | |
Ni–15Cr–11.5Al–3 W–0.2Hf–0.1Si–0.1Mn (γ/γ′/β type) | MBF-80, Ni–Cr–B–Ce (various combinations) | [65] | |
Al-based alloys
| |||
Al A356.0 | Cu | [107] | |
Al 5052 | Ag–Cu | [127] | |
Al 6060 | Al–Cu, Al–Si–Cu | [165] | |
Al 6061 | Ag, Al–Si, BAg-8 | ||
Al 6082 | Cu, Ga | ||
Al 7475 | Zn | [30] | |
Al–7.5Si | Cu | [107] | |
Fe-based alloys
| |||
304 SSc
| Ni–Cr, 304L SSc, BNi-2 | ||
304L SSc
| NB 51 | [91] | |
Duplex SSc
| Cu, Fe–B–Si, Ni–Si–B, MBF-20, MBF-30, MBF-35, MBF-50, MBF-80 | ||
Carbon steel | Cu, Fe–B | ||
Fe–Ni–Cr | Ni–B–Cr–Si (various combinations) | [133] | |
Incoloy MA956 | B, Fe–B–Si | ||
Incoloy MA957 | Fe–B–Si, BNi-1a, BNi-3 | ||
Low carbon steel | Fe–B–Si, BNi-2 | ||
ODSc steel (Fe–Cr–W–Y2O3–Ti) | Fe–Si–B | [131] | |
PM2000 (Fe–Cr–Al) | B, Fe–B–Si | ||
T91 steel | Fe–B–Si, Fe–Ni–Cr–Si–B, BNi-2 | [60] | |
Ti-based alloys
| |||
OT4 | Cu–Ti, Ni–Ti, Ti–Cu–Zr | ||
VT1 | Cu | [46] | |
Ti–6Al–4 V | Cu | [34] | |
Ti–22Al–25Nb (a) | Ti–Cu–Ni | [83] | |
Miscellaneous alloys
| |||
AZ31 (Mg–Al–Zn) | Al, Cu | ||
K640 (Co–Cr–Mo) | Co–Ni–Cr–W–B–Si | [2] | |
Co alloy (unspecified) | Ni–Cr–B | [10] | |
Cu (ODSc) | Cu | Sn | Cu | ||
Cu–Cr–Zr | Cu | Sn | Cu | [110] | |
Sn–Ag | Sn–Bi, Bi–Sn (various combinations) | [106] | |
Single crystals
| |||
Ni | Ni–P | [142] | |
CMSX–2 | F24, MBF-80 | ||
CMSX–4 | D-15, MBF-80 | ||
IC 6 (with and without B) | MBF-80 | [53] | |
PWA 1483 (Ni–Cr–Co–Ta–Ti–W–Al–Mo) | Ni–Ge | ||
Intermetallics
| |||
Ni–45Ti–6Cu | Cu | [32] | |
NiAl | Ni (glaze), BNi-3 | ||
Ti–42Al–2Cr | Ti | Cu, Ti | Ni, Ti | Fe | [51] | |
Ti–45Al–2Nb–2Mn (a) + 0.8 vol.% TiB2
| Ti–Cu–Ni, Cu–Ni | Ti | Cu–Ni | [20] | |
γ-TiAl [Ti–47Al–2Cr–2Nb (a)] | Tini 67 | [40] | |
Ti–48Al–2Cr–2Nb (a) | Cu, Cu & Ti–Al–Cr–Nb, Cu & TiAl | ||
Gamma Met PX | Cu & Gamma Met | [95] | |
Pure metals
| |||
Ag | Cu, Ag–Cu | ||
Al | Ag, Cu, Ga, Al–Cu, Al–Si–Cu | ||
Au | Au–Sn, Sn, In, Ti | In | ||
Cu | Ag, Sn, Ag–Cu, BiIn, BiIn2, BiSn, InSn, NB 51 | ||
Fe | Sb, Fe–P, Fe–B | ||
Nb | Ti, Zr, V | [155] | |
Ni | B, Cu, Hf, BNi-3, BNi-6, MBF-60, MBF-80 | ||
Sn | Bi | [103] | |
Metal matrix composites
d
| |||
Al/Al2O3
| Ag, Cu, Al–Cu, Cu–Ti | ||
Al/SiC | Cu, Ni | [144] | |
Al 2124/SiC | Ni | [48] | |
Al 2618/SiC | Al–Ag–Cu, Al–Ag–Cu–Ti | ||
Al 6061/Al2O3
| Cu | ||
Al 6061/SiC | Cu | ||
AZ91D (Mg–Al)/TiC | Al, Cu | ||
Haynes 230/Al2O3
| Haynes 230 doped with B | [85] | |
Ti–6Al–4 V/SiC | Cu–Ti–Zr | [73] | |
Ceramics
| |||
Al2O3
| Al, Al & SiO2, B2O3
| ||
SiC | Ge | [171] | |
Si3N4
| Oxynitride glass | [185] | |
TiO2
| Bi2O3
| [89] | |
Dissimilar metals
| |||
Al 7075 | Ti–6Al–4 V | Cu | [23] |
Astroloy | Mar-M247 (directionally solidified) | BNi-3 | [124] |
AZ31 (Mg–Al–Zn) | 316L SSc
| Ni | [120] |
Be | Cu–Cr–Zr and Cu (ODSc) | Cu | Sn | Cu | [110] |
Cu | Cu–W composite | Al | [31] |
Cu | Steel | BAg-8 | [160] |
Cu | 304 SSc
| Ag | [10] |
Cu | 304L SSc
| Ag | [109] |
Br.Kh. (Cu–Cr) | 12Kh18N10T (Fe–Cr–Ni) | Cu–Mn|Ni, Cu–Ag|Ni | [111] |
CMSX-4 | Inconel 738 and 939 | BNi-3, Niflex-110, Niflex-115 | |
DD98 (Ni–W–Co–Mo–Ti–Al–Ta–Hf) | M963 (Ni–W–Co single crystal) | Ni–Cr–B | [128] |
Inconel 718 | Inconel X-750 | BNi-2 | [11] |
Mar-M247 | NiAl | Cu | |
Mar-M247 | NiAl-Hf (single crystal) | Cu, NiAl & Cu, Ni3Al & Cu | |
Ni | NiAl | Cu, BNi-3 | |
Low carbon steel | Ti | Cu–Mn–Ni | [49] |
SSc 321 | Zircaloy-4 (Zr–Sn) | Ti–Zr–Cu–Ni | [172] |
Steel | 304L SSc
| Cu | [160] |
TS7 (Ti alloy) | 5VMTs (Nb alloy) with W, Mo, & Zr; and TV10 (Ta alloy) with W | Cu–Ni | [112] |
Ti–42Al–2Cr | Ti 6242 | Ti|Cu, Cu|Ti | [29] |
Ti–6Al–4 V | Ti–45Al–2Nb–2Mn (a) + 0.8 vol.% TiB2
| Cu–Ni, Ti–Cu–Ni | [20] |
Metals to Metal matrix composites
d
| |||
Al 6082 | Al 359/SiC | Cu | [21] |
Ti–6Al–4 V | Ti–6Al–4 V/SiC | Cu–Ti–Zr | [73] |
Metals to Ceramics
| |||
Kovar (Fe–Ni–Co) | SiC | Ni–Si | Mo | [116] |
ODSc Fe alloy (Fe–Cr–Al–Y2O3) | Si3N4
| Fe–B–Si | [72] |
W18Cr4 V tool steel | TiC–Al2O3 composite | Cu|Ti | [28] |
Inconel 718 | Si3N4
| Ni|Cu|Ti | [196] |
Ni | Ti(C,N) (50%TiC & 50%TiN) | Cu|Nb | [132] |
Ti | AlN | Ag–Cu | [52] |
Metal matrix composites
d
to ceramics
| |||
Al 6061/Al2O3
| Al2O3
| Cu |
Variants of TLP bonding
-
Wide-gap TLP bonding: gaps of 100–500 μm can be bonded or repaired by the use of a melting and a non-melting constituent (multiple layers or mixed powders) [7, 16, 57, 92, 94‐96, 100, 101, 136, 149, 173, 195]. This technique can also be used in conventional TLP bonding to accelerate isothermal solidification [13, 99, 140]
-
Partial TLP bonding (see next section).
Partial transient liquid phase (PTLP) bonding
PTLP bonding process
Substrate | Interlayera Combination(s) | Reference(s) | |
---|---|---|---|
Ceramics
| |||
Al2O3
| Cr | Cu | Ni | Cu | Cr, Cu | Nb | Cu, Cu | Ni | Cu, Cu | Ni–Cr | Cu, Cu | Pt | Cu, In | Ag ABAc | In, In | Cusil ABAc | In, In | Incusil ABAc | In, Ni | Nb | Ni, Ti | Al | Ti | ||
Glass | Au | InBi | Au | [139] | |
Si3N4
| Al | Ti | Al, Au | Ni–Cr | Au, Cu–Au | Ni | Cu–Au, Co | Nb | Co, Co | Ta | Co, Co | Ti | Co, Co | V | Co, Cu–Au–Ti | Ni | Cu–Au–Ti, Cu–Ti | Pd | Cu–Ti, Ni | Ti | Ni | Ti | Ni, Ni | V | Ni, Ti | Au | Cu | Au | Ni | Au | Cu | Au | Ti, Ti | Cu | Ti, Ti | Cu | Ni | Cu | Ti, Ti | Ni | Ti, Ti | Ni | 304SSc | Ni | Ti, Ti | Ni | Kovarc | Ni | Ti, V | Co | V | ||
SiC | C | Si | C, Cu–Au–Ti | Ni | Cu–Au–Ti, Ni–Si | Mo | Ni–Si, Ti | Au | Cu | Au | Ni | Au | Cu | Au | Ti | ||
WC | Zn | Pd | Zn | [219] | |
Y2O3-stabilized ZrO2
| Al | Ni | Al, Ni | Nb | Ni | ||
ZrO2-toughened Al2O3
| Ni | Nb | Ni | [216] | |
Composites
b
| |||
Al / SiC | Cu | Ni | Cu | [144] | |
Si3N4 / TiC | Ti | Ni | Ti | [203] | |
Al 6061 / Al2O3
| Cu | Ni | Cu | [209] | |
C / C | Ti | Ni | Ti | [226] | |
Metals to ceramics
| |||
FA-129 (Fe3Al alloy, Fe–Al–Cr–Nb) | Si3N4
| Cu–Ti (ABAc) | Cu | Cu–Ti (ABAc), Cu–Ti | Cu | Ni | Al | |
Kovarc
| Al2O3
| Ni | Ti | Ni | [200] |
Ni | Si3N4
| Ti | Ni | Ti | [225] |
Si | Al2O3
| Ti | Cu | Sn | Au | Cu | [229] |
PTLP bonding kinetics
Advantages and disadvantages of PTLP bonding
-
because diffusion occurs on a smaller scale (on the order of 100 μm), bonding using slow-diffusing elements occurs in a reasonable amount of time.