Design and Fabrication of Small-Scale Diffusion Bonding Apparatus for Regular and Irregular Shaped Parts

Abstract

In this report the innovative design and fabrication of diffusion bonding apparatus is presented. Testing of apparatus by forming a joint between metals is discussed in the report. Initially the parameters were identified and conditions for appropriate bonding of Mild steel and Brass were documented and were used for testing. The parameters identified were then validated from literature. After parameters validation, the optimum design of vacuum chamber based on the simulations was created. The drawings and model of the chamber created are presented in this report. Along with the design, the simulations done in the process of design are also presented in this report. The chamber’s wall thickness was decided to be 12.7 mm based on the simulations but later due to changes in fabrication process thickness of 3mm was used. A reasonable FOS for the vacuum chamber for pressure loadings was obtained. In the next section 3D models of the Pressing assembly, vacuum chamber and coil were given for fabrication process. Then the induction coil constraints for the optimum operations were calculated and heating-coil was sourced. Heating coil along with the module and control system were mounted on vacuum chamber. Then the vacuum chamber along with the heating coil system was assembled and tested.