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Heating Apparatus & Method: “High Speed Diffusion Bonding

Conventional Diffusion or Solid State Bonding, creates a "perfect" joint and cannot be discerned under the microscope. It is an expensive process and requires a significant investment in capital equipment, namely diffusion bonding pressure-vessel and furnace. It also requires significant consumables, such as energy (heat) and argon gas. Cycle times are long, 8 hours of soak-time, followed by cooling. Here, the inventors proposed a local heating method based on non-contact (induction heating), and a vacuum, together with insulation to keep heat in the metal sheets being bonded. The process parameters, have been optimised through finite-element simulation and advanced modelling using high performance computing. This has allowed us to create perfect joints in less than a minute, and some in 30 seconds, using Titanium 64 sheet materials, appropriate for aerospace applications. Early work was with partners Ajax Tocco (Birmingham), UNIPART (Coventry), Rolls-Royce, BAe Systems and UTC HS Marston. The research has successfully demonstrated that a lower capital equipment cost process is feasible, through the developed test rig demonstrator for the bonding process. The method has been patent registered.

This has created much interest, and linked with our work on chemical etching, this has allowed us to join intricately shaped micro-components almost perfectly with minimal deformation. One can imagine joining a stack of sheets with mirco features, to create complex and lightweight components. Other processes have failed to do this, and we believe that this is a significant breakthrough in manufacturing technology. Applications include being able to manufacture micro-channel heat exchangers, parts with complex internal structures and structured new materials.

Investment to date from grants and industry approximately £600k. Our process MRL currently at level 3. Several companies involved in commercialisation and future market, including Ajax Tocco, Chris Kenward:Tel: 07795613933, also ACE, MD: Alan Rollason: Tel: 0781119717.