Diffusion Welding of Similar and Dissimilar Alloys: Review Article

Diffusion welding has emerged as a promising solid-state joining technique, particularly in applications where high heat input from fusion welding can introduce defects and negatively affect the properties of base materials. This process operates at lower temperatures than fusion welding, thereby preserving the mechanical properties of the joined materials. The success of diffusion welding relies on critical parameters such as temperature, pressure, time, and surface preparation. While it is an established method for joining similar alloys, its application to dissimilar alloys presents unique challenges, including differences in thermal expansion coefficients, melting points, and the potential formation of brittle intermetallic compounds. This review article aims to consolidate existing research on diffusion welding of similar and dissimilar alloys, providing a comprehensive understanding of the process and its parameters. Through critical analysis and evaluation of previous studies, the article proposes new inferences based on combined findings. It draws conclusions that will guide future experiments and applications, particularly in industries where precision and material integrity are paramount requirements, such as aerospace, automotive, and power generation. The application of diffusion welding as a reliable alternative to fusion welding highlights its potential to overcome the limitations of the high-heat-input process and enable successful joining of diverse/dissimilar material combinations.