The Effect of Processing Variables on Powder Interlayer Bonding in Nickel-Based Superalloys

Powder Interlayer Bonding (PIB) has been considered as a lower-energy joining technology for nickel-based superalloys compared to conventional methods; such as friction welding. Typically; nickel-based superalloys exhibit high energy requirements for joining due to their high operating temperatures. However; PIB utilizes a localized temperature gradient created by an induction current; reducing the energy requirements for the process. PIB is a solid-state joining method that compresses and heats a powder interlayer between two faying surfaces to produce one joined workpiece. It has been successfully used to bond titanium alloys; and the objectives of this work were to explore its application as a joining method for nickel-based superalloys. Initial results showed that joining nickel-based superalloys via PIB is possible; and bondlines with very little porosity were observed. Further analysis showed that these bonded areas had lower porosity than the base material; suggesting PIB could be a successful joining method for difficult-to-join nickel-based superalloys.