Non-vacuum Diffusion Bonding Technology for TC4 Alloy Water-cooling Plates

YU Tanbo; HOU Rui; LU Zhen; JIANG Shaosong

doi:10.3969/j.issn.1674-6457.2026.09.008

PDF(2502 KB)

Journal of Netshape Forming Engineering ›› 2026, Vol. 18 ›› Issue (9) : 73-79. DOI: 10.3969/j.issn.1674-6457.2026.09.008

Advanced Joining Technology

Non-vacuum Diffusion Bonding Technology for TC4 Alloy Water-cooling Plates

YU Tanbo^1,2, HOU Rui¹, LU Zhen^1,*, JIANG Shaosong¹

Author information +

History +

Abstract

To address the challenge of fabricating large‑scale, complex internal‑flow‑channel TC4 titanium alloy water‑cooling plates in fields such as shipbuilding, where conventional vacuum hot‑pressing diffusion bonding equipment is limited by size and cannot achieve integral forming, the work aims to conduct a hot‑pressing diffusion bonding process under non‑vacuum conditions, proposing a high‑quality, high‑efficiency diffusion bonding method suitable for large titanium alloy water-cooling plate structures. A non‑vacuum diffusion bonding process based on “internal vacuum pumping+inert gas dynamic protection” was adopted. Firstly, small‑scale experiments under various temperatures and pressures were conducted to study the effect of process parameters on interfacial bonding rate and microstructure, thereby optimizing the process parameters. Subsequently, with a superplastic forming machine, the TC4 cover plate and base plate were sealed by welding, internally evacuated, and continuously protected by argon gas, followed by hot‑pressing diffusion bonding in a non‑vacuum furnace chamber. Finally, the formed component underwent dimensional inspection, air‑tightness and hydraulic pressure tests, and scanning electron microscopy (SEM) was employed to analyze the interfacial microstructure and evaluate the bonding quality. The optimal process parameters were determined as 900 ℃, 3.5 MPa, and 60 min, under which the bonding rate reached 99% with no defects at the interface, achieving complete metallurgical bonding. A TC4 water‑cooling plate with overall dimensions of 470 mm×395 mm and an average thickness of 28.14 mm was successfully fabricated under non‑vacuum conditions, with dimensional errors within ± 2 mm. The component passed both 0.5 MPa air‑tightness and 5.0 MPa hydraulic pressure tests without leakage, meeting the requirements for high‑pressure cyclic service. Microstructural analysis revealed complete disappearance of the original interface, sufficient atomic diffusion between the two materials, and a defect‑free interface region. By establishing a local vacuum and inert gas protective environment inside the flow channels, the non‑vacuum diffusion bonding process achieves interface quality comparable to that of vacuum diffusion bonding. This method effectively avoids interfacial micro‑cracks and oxidation defects caused by insufficient gas protection in the machined flow‑channel grooves during prolonged pressing in conventional vacuum hot‑pressing, thereby enhancing the integrity and service reliability of the joint. The process provides a feasible technical route for the efficient and stable manufacturing of large‑scale, complex titanium alloy cooling structures.

Key words

TC4 titanium alloy / diffusion bonding / non-vacuum process / water-cooling plate

Cite this article

EndNote

Ris (Procite)

Bibtex

Download Citations

YU Tanbo, HOU Rui, LU Zhen, JIANG Shaosong. Non-vacuum Diffusion Bonding Technology for TC4 Alloy Water-cooling Plates[J]. Journal of Netshape Forming Engineering. 2026, 18(9): 73-79 https://doi.org/10.3969/j.issn.1674-6457.2026.09.008

References

[1] LOU K L, ZHU M, YUAN Y F.Corrosion Characteristic of Ti-6Al-4V Alloy Imposed with AC Interference in Simulated Seawater Containing Thiosulfate[J]. Materials Today Communications, 2026, 50: 114571.
[2] SUN W T, YANG X M, LIU S Q, et al.Research on Forming Mechanism and Hot Working Diagram of TC4 Alloy in Multilayer Sheet Hot Stamping and Cold Die Process[J]. Journal of Materials Engineering and Performance, 2026, 35(20): 20156-20172.
[3] SUN Z Y, DUAN J Y, WU X, et al.Mechanical Properties and Fracture Behavior of Hot Isostatically Pressed TiC/TC4 Composites[J]. Materials, 2025, 18(24): 5529.
[4] YANG Z H, BAI Y J, CHEN H, et al.Interfacial Characteristics and Mechanical Properties of Al₂O₃ Ceramic/TC4 Alloy Joints Diffusion Bonded with an Aluminum Interlayer[J]. Ceramics International, 2025, 51(30): 64744-64758.
[5] LI T L, ZHOU F J, LONG L Z, et al.Fatigue Crack Growth and Mechanical Properties of Laminated TC4/ TB8 Titanium Alloys Fabricated by Diffusion Bonding[J]. Materials Characterization, 2023, 200: 112825.
[6] 刘宏伟, 蒋青, 郑敏, 等. 焊接角度对TA15钛合金激光填丝焊接头组织性能的影响[J]. 精密成形工程, 2025, 17(12): 227-240.
LIU H W, JIANG Q, ZHENG M, et al.Effect of Different Welding Angles on the Microstructure and Properties of TA15 Titanium Alloy Joints Fabricated by Laser Wire Filling Welding[J]. Journal of Netshape Forming Engineering, 2025, 17(12): 227-240.
[7] WANG J L, PENG W J, LIU T L, et al.Fatigue Failure Analysis for Marine Propeller Used Titanium Alloy under Salty-Water Environment with the Effect of Corrosion Durations[J]. Engineering Failure Analysis, 2025, 179: 109805.
[8] YUAN L H, YANG M Y, LI Y, et al.Nondestructive Texture Measurement of As-Received Ti Alloy Tubing via Simultaneous Shaping and Tilting Defocusing Correction[J]. Journal of Materials Engineering and Performance, 2020, 29(8): 5080-5087.
[9] WANG K H, LIU G, YUAN S J.Deformation Behaviour of Laser-Welded Tube Blank of TA15 Ti-Alloy for Gas Forming at Elevated Temperature[J]. MATEC Web of Conferences, 2015, 21: 06005.
[10] WANG C, TIAN Z Z, ZHANG Q, et al.Numerical Simulation and Experimental Study of Hot-Spinning Damage Characteristics of TC4 Titanium Alloy Tube[J]. Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science, 2025, 239(15): 5978-5989.
[11] CI J C, CHEN S C, JIA H, et al.Axial Compression Performance Analysis and Bearing Capacity Calculation on Square Concrete-Filled Double-Tube Short Columns[J]. Marine Structures, 2020, 72: 102775.
[12] 张琪, 罗丽蓉, 刘涛, 等. 船舶海水管系TC4钛合金的表面涂层与耐蚀性能[J]. 金属热处理, 2019, 44(1): 185-189.
ZHANG Q, LUO L R, LIU T, et al.Surface Coating and Corrosion Resistance of TC4 Titanium Alloy in Marine Tube System for Ship[J]. Heat Treatment of Metals, 2019, 44(1): 185-189.
[13] SUN Y H, ZHU Z X, WANG Q, et al.Strength-Ductility Trade-off in TiB-TC4 Composites with a Pseudo Core- Shell Structure[J]. Journal of Materials Research and Technology, 2023, 27: 574-584.
[14] HOSSEINNIA S M, AMIRI L, NESREDDINE H, et al.An Iterative Approach for Optimum Sizing and Off- Design Performance Analysis of Water-Cooled Brazed Plate Heat Exchanger as Supercritical CO₂ Gas Cooler[J]. International Journal of Refrigeration, 2025, 180: 199-221.
[15] 钟立才, 胡敏哲. 钛合金材料的耐压壳体在船舶建造中的应用研究[J]. 信息记录材料, 2021, 22(6): 6-7.
ZHONG L C, HU M Z.Study on the Application of Pressure-Resistant Shell Made of Titanium Alloy in Ship Construction[J]. Information Recording Materials, 2021, 22(6): 6-7.
[16] BIELSKI P, DOROSZKO M, SEWERYN A.Failure Mechanisms and Strength of Mesostructurally Modified Ti-6Al-4V Lattice Metamaterials Designed for Additive Manufacturing[J]. Engineering Failure Analysis, 2026, 186: 110478.
[17] CAI Y, SONG Y W, DONG K H, et al.Threshold Potential for Hydrogen-Induced Damage of Ti-6Al-4V Alloy under Deep-Sea Environment: A Mechanistic Insight[J]. Acta Materialia, 2026, 304: 121792.
[18] LI N Q, FAN S M, DUAN Y H, et al.Interface Characteristics of Microporous Al-Cr Diffusion Layers to Improve Wear Resistance of Ti-6Al-4V[J]. Tribology International, 2026, 215: 111497.
[19] YANG K, QIN Q D, LI J, et al.Effect of Temperature on Microstructure and Mechanical Properties of CoCrFeNi/ TC4 Diffusion-Bonded Joints[J]. Journal of Materials Engineering and Performance, 2026, 35(11): 10859-10868.
[20] LI C, ZHANG D X, LI X X, et al.Fracture Behavior in Tensile and Fatigue Tests of Diffusion Bonded TC4 Titanium Alloy at Room and High Temperatures[J]. Engineering Failure Analysis, 2025, 182: 110182.
[21] WANG Y C, LI P, ZHAO C H, et al.A Novel High Entropy Composite Interlayer for Diffusion Bonding of TC4 Titanium Alloy to 316L Stainless Steel[J]. Materials Today Communications, 2024, 41: 110291.
[22] PENG Y, LI J L, LI Z X, et al.Interfacial Voids and Microstructure Evolution, Bonding Behavior and Deformation Mechanism of TC4 Diffusion Bonded Joints[J]. Journal of Manufacturing Processes, 2022, 81: 837-851.
[23] FENG G J, WEI Y, HU B X, et al.Vacuum Diffusion Bonding of Ti₂AlNb Alloy and TC4 Alloy[J]. Transactions of Nonferrous Metals Society of China, 2021, 31(9): 2677-2686.
[24] JEON S, HA H, LEE D J, et al.High-Integrity Diffusion Bonding of Laser Powder Bed Fused, Forged, and Rolled Ti-6Al-4V Alloys[J]. Journal of Materials Research and Technology, 2025, 35: 2108-2118.
[25] PRIKHODKO S V, SAVVAKIN D G, MARKOVSKY P E, et al.Diffusion Bonding of TiC or TiB Reinforced Ti-6Al-4V Matrix Composites to Conventional Ti-6Al- 4V Alloy[J]. Science and Technology of Welding and Joining, 2020, 25(6): 518-524.
[26] MO D F, SONG T F, FANG Y J, et al.A Review on Diffusion Bonding between Titanium Alloys and Stainless Steels[J]. Advances in Materials Science and Engineering, 2018, 2018(1): 8701890.
[27] 王海强, 王坤, 叶福田. Ti-55钛合金三层空心结构件的超塑成形/扩散连接工艺研究[J]. 模具技术, 2016(1): 6-8.
WANG H Q, WANG K, YE F T.Superplastic Forming and Diffusion Bonding Process for Hollow Three-Sheet Structure of Ti-55 Alloy[J]. Die and Mould Technology, 2016(1): 6-8.
[28] 孙超. TC4钛合金中空叶片扩散连接-超塑成形技术[D]. 哈尔滨: 哈尔滨工业大学, 2014: 28-31.
SUN C.DB-SPF processing of hollow blade for TC4Titanium alloy[D]. Harbin: Harbin Institute of Technology, 2014: 28-31.
[29] HAN W B, ZHANG K F, WANG G F.Superplastic Forming and Diffusion Bonding for Honeycomb Structure of Ti-6Al-4V Alloy[J]. Journal of Materials Processing Technology, 2007, 183(2/3): 450-454.