Diffuse compound materials. (1983)

Landing of a jet plane.

Landing of an Aeroflot passenger plane.

When an airplane lands, a huge flow of energy is broken on thin brake pads.

Only cast iron and cermets can withstand such loads.

Cast iron and metal-ceramic brake pads are welded to the steel wheels.

Such materials are not welded by conventional welding methods.

Cast iron and cermet with steel can be turned into a monolith by diffusion coupling in vacuum.

A device for performing such an operation.

During the test, the material is destroyed not in the welding zone, but in the base material.

The diffusion method, unlike conventional welding, made it possible to connect almost all materials.

For example, the discorotor of an electric motor is welded from non-magnetic and magnetic steel.

The welding zone is almost indistinguishable.

The glass is welded with metal.

The surface of the part is clad with a thin layer of silver.

A part made of metal ceramics.

Ceramics are connected to copper.

Previously, it was possible to connect such materials only by soldering or gluing.

Diffusion welding does not require scarce solders and provides vacuum density.

The strength in the diffusion layer is higher than that of the base material.

The author of the new welding method is Doctor of Technical Sciences, Professor N.F. Kozakov.

Demonstration of patents.

A cartoon explaining the physical basis of the method.

Vacuum installation for welding.

Components of the installation.

Installations differ by the type of heating of parts and by the method of pressure transmission.

About 70 types of diffusion plants have been developed.

An important advantage of these installations is ease of maintenance and environmental friendliness.

Samples of parts welded by melting and diffusion.

During diffusion welding, the parts do not deform and use less electricity.

Bearing details.

A ball sample from a bearing connected by diffusion welding.

Three types of joining materials during diffusion welding.

Example, the connection of cast iron with steel.

A snapshot of the connection of materials taken under an electron microscope.

To prevent the formation of intermetallic phases, to obtain a strong connection, an intermediate layer is introduced into contact.

The gasket or intermediate layer is selected in advance and applied by different methods.

Gaskets contribute to lowering the welding temperature, reducing internal stresses.

The thinnest layer of such gaskets is enough to prevent the appearance of brittle phases.

In the process of diffusion welding, a pre-prepared package of gaskets is used.

This makes it possible for a smoother phase transition when welding dissimilar materials.

The technology of diffusion welding in vacuum is relatively simple.

Surface preparation.

Turning semi-finishing is enough for metal parts.

Roughness control by profilograph- profilometer.

The surfaces of non-metallic parts are usually sanded.

Degreasing the surface of metal parts.

Ultrasonic bath.

The parts are etched in acid.

The parts are installed in the camera in contact with each other.

They are heated, compressed, maintained and cooled.

The part after welding.

Connection quality control.

Universal method of ultrasonic parts control.

The screen shows a marriage in the connection.

Now active ultrasonic control is increasingly used during the welding process itself.

The sensors of the device are installed inside the vacuum chamber, in direct contact with the part.

The methods of diffusion welding in vacuum are continuously being improved.

Even now, it is possible to combine the assembly of a part and its welding in one process.

A part made of a metal and ceramic joint.

It is possible to mold and weld a metal powder product.

To connect porous materials of different structures without changing their physical and mechanical properties.

Welding multi-position devices are being created, which can significantly increase labor productivity.

Previously, the details of the presented turbine were connected by riveting, now by welding immediately over the entire surface.

At the same time, the quality of the product increases.

In such an installation, alloys containing easily evaporating components can be combined.

Welding is carried out under excessive pressure in an inert gas environment.

Installation with software control.

Samples of the connection of quartz glass with metal, ferrites with metals.

Connection of magnetic hard and soft materials.

Vacuum welding is widely used in the tool industry.

Lathe cutter.

Milling cutter.

A stamp obtained by diffusion welding.

Operation of the vacuum welding unit.

A spaceship takes off into space.

Docking of spacecraft.