Electric Field Assisted Sintering of Bimetallic Materials

A novel method for joining dissimilar metals through electric field assisted sintering, offering a superior alternative to traditional welding techniques.

The Challenge:

In industries where combining dissimilar materials is crucial, traditional welding methods like explosion welding or friction stir welding have significant limitations and high costs. This document presents an innovative alternative: creating bimetallic materials using electric field assisted sintering (EFAS). This technology provides a practical solution mainly for the aerospace, heat transfer, and manufacturing sectors. For example, it allows the fusion of aluminum and stainless steel without the size and cost limitations of traditional connectors.

How it Works:

This technology presents an innovative approach to fabricate bimetallic materials by utilizing electric field assisted sintering (EFAS). It enables the joining of dissimilar materials, such as stainless steel and aluminum, which are challenging to weld by conventional means. Utilizing electric fields, EFAS ablates surface oxides and facilitates controlled diffusion at lower temperatures, allowing for precise bonding without additional interfacing materials, counteracting the risks of galvanic corrosion effectively. The process achieves bonding without the need for bulky mechanical fasteners, explosion welding, or friction stir welding, making it a rapid and efficient alternative for creating bimetallic couplings.

Key Advantages:

• Facilitates the joining of dissimilar materials efficiently.
• Reduces the need for bulky mechanical fasteners, lowering space requirements and leak potential.
• Offers precise control over pressure and temperature, leading to superior bond quality and reproducibility.
• Eliminates the need for consumable materials, setup time, and post-bond processing associated with explosion welding.
• More environmentally friendly and safer than traditional welding methods.

Problems Solved

• Challenges in bonding dissimilar materials with significantly different properties.
• High cost and complexity of traditional bimetallic fabrication methods.
• Limitations in shape and batch size associated with friction stir welding and explosion welding.
• Galvanic corrosion issues arising from the use of interfacing materials.

Market Applications

• Joining aluminum to stainless steel pipes in various industries, eliminating the need for bulky flanges.
• Aerospace industry for joining lightweight aluminum parts to high strength steels without bolts or fasteners.
• Heat transfer applications, benefiting from aluminum's conductivity and stainless steel's toughness.
• Heating and cooling coil manufacturing, where cost reduction can significantly impact market competitiveness.

Development Status: TRL 5

US Provisional Patent Application No. 63/639,461, “METHODS FOR FORMING BIMETALLIC STRUCTURES AND ASSOCIATED STRUCTURES,” BEA Docket No. BA-1510

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