Managing CTE Mismatch in Dissimilar Material Joining

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Back to Core Research Programme AMorph – 4D Printing for Field Morphing Structures Automation of Composite and Hybrid Joining Process Coaxial Wire Additive Manufacturing Processes and In-Line Monitoring Tools Development of Coded Excitation Technique for Non-Metallic Pipes Inspection Development of Digital Twin technology as a demonstrator for real-time integrity assessment of crack growth in tensile specimens Development of Friction Stir Welding (FSW) for Hydrogen Fuel Storage Tanks Development of Leak-Before-Break Hydrogen Storage Composite Pressure Vessels With Polymeric Liner Establishing Assessment Methods for Determining Safe Service Limits of High-Temperature Materials in Extreme Environments Fracture toughness in aggressive environments: effect of crack monitoring techniques on test results In-process detection and non-destructive testing of electron beam weld imperfections Internal Bore Coatings for Applications in Corrosion and Hydrogen Environment Joining of Additively Manufactured Materials Long term behaviour of polymeric liner materials/coatings in hydrogen service Techniques for High Temperature Ultrasonic Inspection of Arc Welding Ultimate Leverage Fund

Project Code: 32887

Start date and planned duration: February 2019, 30 months

Objectives

Develop a practical understanding of the differences between the use of conventional and active metal braze alloys for joining ceramics to metals.
Assess modified braze compositions for improved joint integrity.
Design and assess modified braze structures for improved joint integrity.
Determine the effect of the modified brazing solution on mechanical properties and NDT processes.

Project Outline

The project will investigate options for the creation of a modified brazed joint such that it is possible to better accommodate residual stresses after joining, improving joint integrity, and critically, the size of components that can be joined. We will compare the practical differences between using conventional and specialised braze alloy compositions. Strategies for modifying the properties and structure of the brazed joint will be investigated in order to advance the current state-of-the-art. This may include addition of modifying particles to the brazed joint to change both the physical properties and the structure, in order to produce localised areas of greater ductility. Process variables that will be considered include joint gap, brazing temperature and time and brazing atmosphere.

Industry Sectors

Aerospace
Electronics and Sensors
Medical
Oil and Gas
Power

Benefits to Industry

New concepts for managing CTE mismatch will be used by industry for improved joint design leading to materials and manufacturing efficiencies, saving cost and potentially improving safety.

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