Porosity occurring in diffusion-bonding

Diffusion-bonding is a very attractive process for the strong bonding of dissimilar engineering materials in order to form engineering devices and structures. However, because of the differing diffusion rates of the components, porosity often forms in the bonding zone during fabrication or in-service conditions. This results in a very substantial loss of strength of the bonds that is greatly limiting the uptake of this bonding process to other technologies.

Based on new research into the fundamental principles of inter-diffusion and with the assistance of computer simulation we are developing a robust and versatile theory that will predict the onset and extent of porosity formed during diffusion-bonding and will guide methods for its control.