Interfacial microstructure and mechanical properties of diffusion bonded joints of additive manufactured 17-4 PH stainless steel and TC4 titanium alloy

A novel atomic diffusion additive manufactured 17-4 PH stainless steel and TC4 titanium alloy was successfully joined by vacuum diffusion bonding with Cu foil + Ni foil interlayers at the temperature range of 880°C–960 °C for 60 min with 2 MPa pressure. The interfacial microstructural evolution, interfacial diffusion of elements, and mechanical properties of joints were analyzed. The results indicated that the interfacial transition zone was composed of diffusion affect zone (DAZ) and interface reaction zone (IRZ). With Cu foil + Ni foil composite interlayers, reaction layers such as DAZ 1/IRZ 1/IRZ 2/DAZ 2 were formed in the transition zone, and the interface consisted of CuTi + CuTi2 eutectic phase, CuTi2, Ti (Cu, Ni) and α-Ti. Striped Ti (Cu, Ni) phases were surrounded by serrated CuTi2 phases, which contained Cu-poor, Ni poor areas, and the segregation of Ti atoms. The maximum microhardness of 693 HV0.1 and the maximum shear strength of 163 MPa were obtained at the bonding temperature of 920 °C and 960 °C, respectively.