US3436805A - Method of joining aluminum and ferrous members - Google Patents

Method of joining aluminum and ferrous members Download PDF

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Publication number
US3436805A
US3436805A US478155A US3436805DA US3436805A US 3436805 A US3436805 A US 3436805A US 478155 A US478155 A US 478155A US 3436805D A US3436805D A US 3436805DA US 3436805 A US3436805 A US 3436805A
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Prior art keywords
aluminum
ferrous
temperature
joint
members
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Warren H Friske
Edward C Supan
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Boeing North American Inc
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North American Rockwell Corp
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/001Interlayers, transition pieces for metallurgical bonding of workpieces
    • B23K35/002Interlayers, transition pieces for metallurgical bonding of workpieces at least one of the workpieces being of light metal
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/22Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded
    • B23K20/227Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded with ferrous layer
    • B23K20/2275Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded with ferrous layer the other layer being aluminium
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10STECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S428/00Stock material or miscellaneous articles
    • Y10S428/922Static electricity metal bleed-off metallic stock
    • Y10S428/9335Product by special process
    • Y10S428/934Electrical process
    • Y10S428/935Electroplating
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10STECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S428/00Stock material or miscellaneous articles
    • Y10S428/922Static electricity metal bleed-off metallic stock
    • Y10S428/9335Product by special process
    • Y10S428/938Vapor deposition or gas diffusion
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/12All metal or with adjacent metals
    • Y10T428/1241Nonplanar uniform thickness or nonlinear uniform diameter [e.g., L-shape]
    • Y10T428/12417Intersecting corrugating or dimples not in a single line [e.g., waffle form, etc.]
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/12All metal or with adjacent metals
    • Y10T428/12451Macroscopically anomalous interface between layers
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/12All metal or with adjacent metals
    • Y10T428/12493Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
    • Y10T428/12736Al-base component
    • Y10T428/1275Next to Group VIII or IB metal-base component
    • Y10T428/12757Fe

Definitions

  • the term aluminum includes aluminum metal and its alloys with either metallic or ceramic components such as the commercially available aluminum alloys consisting of about 4-12 wt. percent aluminum oxide dispersed in an aluminum matrix.
  • ferrous metal is intended to designate metals and alloys at least 50% of which are iron, and includes the various types of stainless steel.
  • the principal object of our present in- 3,435,865 Patented Apr. 8, 1969 vention is to provide an improved method of joining ferrous and aluminum members.
  • Another object is to provide such a joint which possesses high strength and gas leak-tight integrity.
  • Another object is to provide an improved method of joining aluminum and ferrous metals which does not require the use of welding or brazing techniques.
  • Another object is to provide a method of joining tubular aluminum and ferrous members.
  • Still another object is to provide a method of joining aluminum and ferrous metals for high temperature applications wherein the formation of brittle, intermetallic aluminum and iron compounds is avoided.
  • a further object is to provide such a method which can be performed relatively quickly and economically and is suitable as a production method.
  • FIG. 1 is a cross section representation of transition joint components
  • FIG. 2 is a cross section of a completed transition joint
  • FIG. 3 is a cross section of an apparatus for fabrication of tubular transition joints.
  • aluminum and ferrous members may be joined by providing a tapered edge on the ferrous member and then contacting it with the aluminum member under pressure at elevated temperature. This results in an effective, leak-tight joint by back-extrusion of the aluminum over the tapered surface of the ferrous member.
  • the deformation of the aluminum surface by the tapered ferrous member at bonding pressures exposes a clean aluminum surface at the joint interface free of surface contamination, which significantly contributes to the formation of the high quality bond.
  • the surface of the contacting edge of the ferrous member is tapered to a cross section width less than that of the cross section of the associated joining surface of aluminum and the taper preferably extends to a knife-edge.
  • FIG. 1 shows the steel 2 and aluminum 4 transition joint components prior to joining, steel member 2 having a double knife-edge 6 with about a 60-75 angle to the edge from the horizontal; knifeedges with other angles may be appropriately used.
  • FIG. 2 is seen a completed transition joint with backextrusion of the aluminum over the ferrous member.
  • interleaf material may be applied to the ferrous or aluminum member (preferably to the knife-edge of the steel) by conventional techniques such as electroplating, vacuum or vapor deposition, and pack cementation; a preplaced foil may also be used.
  • Satisfactory interleaf barrier materials are tantalum, tungsten, molybdenum, niobium, chromium, gold, silver, and nickel, or any combination of two or more thereof.
  • the preferred diffusion barrier materials are niobium, tantalum, and chromium. Thin layers of the diffusion material are employed, for example, in the range of about 0.2-3 mils.
  • the diffusion material functions by preventing contact between the aluminum and steel to avoid formation of iron-aluminum intermetallics; further, there is no eutectic or other compound formation between the barrier material and the aluminum or iron, with the exceptions noted below. There is also no evidence of degrading interdiffu sion after prolonged testing at elevated temperatures.
  • the interleaf material conforms to the shape of the knifeedge and is accordingly deformed during the joining step which is characterized by the back-extrusion of aluminum.
  • the aluminum and ferrous surfaces are joined by hot pressing at elevated temperatures using conventional equipment.
  • the joint components are prepared for bonding by degreasing the surfaces, liquid honing the steel knife-edge, and abrading the aluminum joint area by such means as abrasive paper or a Wire brush.
  • the parts are then rinsed in acetone, alcohol, or the like, and the diffusion barrier material, when employed, is applied on the steel or an interleaf foil placed between the joining surfaces.
  • the joint members are placed in a fixture which maintains conformity of the surfaces, and pressure applied at temperature.
  • the temperature, pressure, and time parameters may satisfactorily vary over a considerable range and are interrelated in that higher pressures or temperatures may compensate for shorter times and vice versa.
  • the particular gonditions are dependent to some measure upon the properties of the alumium and ferrous members.
  • aluminum metal or a low strength aluminum alloy may be bonded to steel at a lower temperature and/or pressure than for higher strength aluminum alloys.
  • the temperature may satisfactorily be about 750-1200 F., under loads of at least about 20,000 psi of cross section of the aluminum member in its non-tapered section, for periods of time of about 3-30 minutes. Good quality joints may be obtained at higher loads, above about 35,000 p.s.i., although no advantage is gained thereby.
  • the preferred temperature for hot pressing is dependent upon the strength of the aluminum, and is one which gives good aluminum flow characteristics during back-extrusion over the tapered ferrous member.
  • the aluminum alloy XAPOOl is bonded in the range of about 900-1150 F.
  • Such other aluminum alloys as Type 6063 may be bonded as low as about 800 F.
  • the upper bonding temperature is, in some cases, limited by the particular diffusion barrier selected, and should be below that which gives a eutectic between aluminum and the barrier material.
  • the only ones of the present barrier materials which form eutectics in the above temperature range are gold (Al-Au, 977 F.) and silver (Al-Ag, 1051" F.) and with such metals bonding is performed below such temperatures.
  • the resulting joined member may then be directly taken to ambient conditions, for example by removing the members from under load into ambient air.
  • the joint is then removed from the fixture and permitted to air cool to ambient temperature.
  • the joint may be cooled at a rate of about F. per minute to 300 F., and preferably at a rate of about 5 F. per minute to room temperature.
  • the hot pressing is conducted in a manner to avoid oxidation of the joint interface.
  • FIG. 3 An apparatus for fabrication of tubular transition joints .4 between ferrous and aluminum tubular members is shown in FIG. 3.
  • the ferrous and aluminum joint components 2 and 4 are placed in the hot pressing apparatus 8, and are radially restrained by an outer die 10 and an inner mandrel 12 positioned on a die base 14.
  • the die set is fabricated from hardened high-speed tool steel (AISI Type T1 or the like).
  • the assembly is heated by an induction coil 16 surrounding the die, and bonding pressure is applied by a hydraulic press 18 acting vertically on stainless steel tube 2.
  • Thermo-couples 20 are positioned in die 10 and mandrel 12 to provide temperature control during hot pressing.
  • This apparatus is positioned in an atmosphere enclosure (not shown) which provides the controlled atmosphere. In one embodiment, such retort is flushed with argon and evacuated by a mechanical vacuum pump prior to the hot pressing operation.
  • Example I An aluminum alloy tube containing approximately 6% A1 0 dispersed in an aluminum matrix (sold under the trade name XAPOOI by The Aluminum Company of America) was extruded, having the dimensions 1.93 in. CD. by 0.117 in. wall thickness, 3 in. length.
  • a similar size Type 304 stainless steel tube had double knifeedges machined at one end of the tube at an angle of 60 from the horizontal.
  • the joint components were prepared for bonding by degreasing, liquid honing the stainless steel knife-edge, and abrading the aluminum joint area, following which the parts were rinsed in alcohol.
  • a 0.3 mil coating of chromium was electroplated onto the stainless steel knife-edge.
  • the tubular components were than placed in the hot pressing apparatus shown in FIG.
  • Isothermal heat treatments were conducted in an air or vacuum atmosphere at a temperature of about 650 F.-950 F. for about 1000-2500 hours in order to determine the extent and effect of any diffusion interaction at the joint interface.
  • Thermal cycling tests were made using various heating and cooling media. For example, joints were subjected to a plurality of cycles (e.g. 10- 1000) of heating in air to 750 F. and quenching in water at room temperature or cooling to room temperature in air. One joint was subjected to 13 air-water cycles without leaking, and other joints remained helium leaktight after cycles from 750 F. to room temperature.
  • helium leak tests were made.
  • the joints were generally helium leak-tight, and such leakage as was observed was very small, of the order of 10' cc. (STP)/sec. of helium.
  • Pressure tests employed argon as the pressurizing medium. Test temperatures ranged from room temperature to 780 F. and pressure at failure ranged from 825 to 1425 p.s.i.g. at estimated hoop stresses of 6700 to 26,- 800 p.s.i.
  • Tensile strength tests were conducted at room temperature, 650 F., and 750 F. on longitudinal segments of transition joints.
  • Ultimate tensile strengths of specimens tested at room temperature range at 20-30 k.s.i., and for specimens tested at 650 F. and 750 F. values ranged from about 5 to 12 k.s.i.
  • Metallographic examinations of the joint cross section in the as-bonded conditions after various thermal treatments showed intimacy of contact at the bond interface between the stainless steel and the aluminum alloy. There was no formation of intermetallic compounds.
  • Example II The procedure of Example I is followed except that no interleaf material is employed and the joint is bonded at a temperature of 950 F. and a pressure of 31,500 p.s.i. aluminum tube cross section for minutes. The joint is subjected to the testing described in Example I, and a bond of similar high quality is determined to have been obtained.
  • Example III The procedure of Example I is followed except that a 1 mil foil of tantalum is used as the interleaf material and the joint is bonded at a temperature of 1050 F. and a pressure of 30,000 p.s.i. aluminum tube cross section for 10 minutes.
  • Example IV The procedure of Example I is followed except that aluminum metal is used, the stainless steel has a 30 knife-edge and a 2 mil niobium foil is used as the interleaf material. The joint is bonded at a temperature of 1000 F. at a pressure of 30,000 p.s.i. aluminum tube cross section for 10 minutes.
  • a method of joining an aluminum member and a ferrous member at corresponding edges which comprises:
  • a method of joining an aluminum member and a ferrous member at corresponding edges which comprises: '(a) providing a tapered edge on the ferrous member, (b) interposing a thin diffusion barrier material between said tapered edge of the ferrous member and a corresponding flat edge of the aluminum member, (c) said barrier material being selected from at least one metal of the class consisting of tantalum, niobium, chromium, gold, silver, nickel, tungsten and molybdenum, and (d) contacting said ferrous and aluminum members with the interposed barrier material at said corresponding edges under sufficient pressure for said interposed barrier material and said tapered edge to penetrate said flat edge and at an elevated temperature below the fusion temperature of said members and below the temperature of eutectic formation of aluminum and said barrier material, (e) said temperature and pressure being suflicient to cause flow of said aluminum over said tapered edge to form a high-strength, leak-tight bond between said members at their contacting edges.
  • said diffusion barrier is selected from the class consisting of tantalum, niobium and chromium.
  • ferrous member is stainless steel and said aluminum member is an alloy consisting essentially of about 4-8 wt. percent A1 0 distributed in an aluminum matrix, and said members are bonded together at a temperature of about 900- 1150 F. under a load of about 25,000-35,00 0 p.s.i. for a period of about 3-30 minutes in an inert environment.
  • a method of forming a joint between tubular members of steel and aluminum at corresponding ends which comprises:
  • barrier metal being selected from the class consisting of tantalum, niobium, chromium, gold, silver, nickel, tungsten and molybdenum,
  • a method of forming a joint between corresponding ends of tubular members of stainless steel and an aluminum alloy consisting essentially of about 4-8% A1 0 dispersed in an aluminum matrix which comprises:

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  • Mechanical Engineering (AREA)
  • Pressure Welding/Diffusion-Bonding (AREA)
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US478155A 1965-08-09 1965-08-09 Method of joining aluminum and ferrous members Expired - Lifetime US3436805A (en)

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Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3528166A (en) * 1967-04-14 1970-09-15 Euratom Process for the welding of metal objects
US3630694A (en) * 1969-10-29 1971-12-28 Du Pont Aluminum/ferritic stainless steel/steel composites
US3650710A (en) * 1968-09-25 1972-03-21 Soc De Traitements Electrolytiques Et Electrothermiques Element with a laminated metal structure
US3653852A (en) * 1969-10-14 1972-04-04 Bethlehem Steel Corp Coated ferrous substrate
US3766633A (en) * 1970-12-10 1973-10-23 Kernforschungsanlage Juelich Method of joining metals of different melting points
WO1985001684A1 (en) * 1983-10-13 1985-04-25 Moe Per H A method for joining tubular parts of metal by forge/diffusion welding
EP1563941A1 (en) * 2004-02-17 2005-08-17 Nissan Motor Co., Ltd. Liquid phase diffusion bonding method for dissimilar metal sheets and liquid phase diffusion bonding apparatus for the same
CN102114561B (zh) * 2009-12-31 2013-06-05 南京理工大学 铝-钢螺柱预镀铜感应熔钎焊方法
US20200030907A1 (en) * 2017-08-29 2020-01-30 Origin Company, Limited Method for manufacturing dissimilar metals-joined article and joining apparatus

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1352317A (en) * 1970-03-06 1974-05-08 Gkn Floform Ltd Method of making semi-conductor mounts
JP3546261B2 (ja) * 1996-03-05 2004-07-21 ヤマハ発動機株式会社 異種金属材料の接合方法

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2535397A (en) * 1948-04-08 1950-12-26 Duch Gabriel Victor Alphonse Method for electrically interconnecting wires cables, tubes plates, and other metallic elements
US2763058A (en) * 1952-01-07 1956-09-18 Bohn Aluminium & Brass Corp Process of producing steel-aluminum bi-metal strip
US2809422A (en) * 1954-05-21 1957-10-15 Gen Motors Corp Method of making a composite article
US2908073A (en) * 1957-06-07 1959-10-13 Aluminum Co Of America Method of bonding aluminous metal to dissimilar metal
US2917818A (en) * 1954-12-29 1959-12-22 Gen Motors Corp Aluminum coated steel having chromium in diffusion layer
US3292256A (en) * 1964-04-09 1966-12-20 Allegheny Ludlum Steel Pressure bonding of dissimilar metals
US3367020A (en) * 1965-05-19 1968-02-06 Robert D. Watson Method of preparing tubes of certain metals for subsequent joining by welding

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2535397A (en) * 1948-04-08 1950-12-26 Duch Gabriel Victor Alphonse Method for electrically interconnecting wires cables, tubes plates, and other metallic elements
US2763058A (en) * 1952-01-07 1956-09-18 Bohn Aluminium & Brass Corp Process of producing steel-aluminum bi-metal strip
US2809422A (en) * 1954-05-21 1957-10-15 Gen Motors Corp Method of making a composite article
US2917818A (en) * 1954-12-29 1959-12-22 Gen Motors Corp Aluminum coated steel having chromium in diffusion layer
US2908073A (en) * 1957-06-07 1959-10-13 Aluminum Co Of America Method of bonding aluminous metal to dissimilar metal
US3292256A (en) * 1964-04-09 1966-12-20 Allegheny Ludlum Steel Pressure bonding of dissimilar metals
US3367020A (en) * 1965-05-19 1968-02-06 Robert D. Watson Method of preparing tubes of certain metals for subsequent joining by welding

Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3528166A (en) * 1967-04-14 1970-09-15 Euratom Process for the welding of metal objects
US3650710A (en) * 1968-09-25 1972-03-21 Soc De Traitements Electrolytiques Et Electrothermiques Element with a laminated metal structure
US3653852A (en) * 1969-10-14 1972-04-04 Bethlehem Steel Corp Coated ferrous substrate
US3630694A (en) * 1969-10-29 1971-12-28 Du Pont Aluminum/ferritic stainless steel/steel composites
US3766633A (en) * 1970-12-10 1973-10-23 Kernforschungsanlage Juelich Method of joining metals of different melting points
WO1985001684A1 (en) * 1983-10-13 1985-04-25 Moe Per H A method for joining tubular parts of metal by forge/diffusion welding
EP1563941A1 (en) * 2004-02-17 2005-08-17 Nissan Motor Co., Ltd. Liquid phase diffusion bonding method for dissimilar metal sheets and liquid phase diffusion bonding apparatus for the same
US20050178819A1 (en) * 2004-02-17 2005-08-18 Nissan Motor Co., Ltd. Liquid phase diffusion bonding method for dissimilar metal sheets and liquid phase diffusion bonding apparatus for the same
US7119309B2 (en) 2004-02-17 2006-10-10 Nissan Motor Co., Ltd. Liquid phase diffusion bonding method for dissimilar metal sheets and liquid phase diffusion bonding apparatus for the same
CN102114561B (zh) * 2009-12-31 2013-06-05 南京理工大学 铝-钢螺柱预镀铜感应熔钎焊方法
US20200030907A1 (en) * 2017-08-29 2020-01-30 Origin Company, Limited Method for manufacturing dissimilar metals-joined article and joining apparatus

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DE1577101A1 (de) 1970-04-09
BE685260A (enrdf_load_html_response) 1967-01-16
JPS4932692B1 (enrdf_load_html_response) 1974-09-02
NL6611175A (enrdf_load_html_response) 1967-02-10
SE321839B (enrdf_load_html_response) 1970-03-16
GB1150005A (en) 1969-04-30
ES330032A1 (es) 1967-06-16

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