Bulk-like Joints by Gas Actuated Bonding

Introduction

In this project, I will develop a novel concept and new understanding of metal joining through the use of chemical gases. In this concept, chemical vapour transport (CVT) technology is unconventionally used to induce a transient liquid phase that could form joints with greatly enhanced mechanical and anti-corrosion properties.

Current Challenges in Metal Joining

In metal joining, a continuous metallic phase must bridge two parts, but current bridging phases are weaker and more prone to corrosion than the materials from which the components are made. This shortens the lifespan in harsh environments, and new avenues need to be explored.

Preliminary Data

My preliminary data show that it is possible to:

1. Induce a transient liquid phase by
2. Exposing metal surfaces to melting point depression element (MPD) precursor gases, using
3. Chemical vapour transport technology.

Expected Outcomes

The concept will result in joints made from the bulk material itself; hence both joint and bulk obtain the same surface oxide and microstructure, leading to the best possible corrosion resistance and strength.

Research Methodology

In this project, in-situ characterisation will be used to improve our understanding of chemical vapour technology for processing metals and their oxides. Benefiting from this knowledge, and the production of small components for testing fundamental properties and evaluating performance, I will discover the mechanisms in, and create models for, CVT alloying as well as identify the properties of the novel joints.

Application of Research Results

To ensure a wide application of research results, I will investigate the joints in corrosive settings, targeting the demanding environments found in:

• Solar thermal energy storage
• Solid oxide fuel cells
• Fossil-free steel production

This novel joining concept could also revolutionise the manufacturing of small, complex, and high-performing equipment, as difficult-to-join alloys could thus be used in difficult-to-manufacture components. Such components are found in turbine engines, medical equipment, and sensor technology.