Transient Liquid Phase Bonding of Hastelloy X with Inconel 738 Superalloy Using BNi-2 Interlayer: Microstructure and Mechanical Properties

The dissimilar joining of solid-solution-strengthened superalloys and precipitation-strengthened superalloys enables complementary performance synergy, holding significant application potential in the aerospace industry. This study investigated the transient liquid phase bonding of Hastelloy X and IN738 using a BNi-2 interlayer, focusing on the effects of bonding temperature and time on interfacial microstructure evolution and mechanical properties. The results demonstrated that achieving complete isothermal solidification is paramount for joint properties, a process governed by the synergistic control of bonding temperature and time. At lower temperatures (e.g., 1050 °C), the joint centerline contained an athermal solidification zone (ASZ) rich in hard and brittle Cr-rich (∼15.9 GPa) and Ni-rich borides, which served as the failure initiation site. As the ASZ was progressively eliminated with increasing temperature, a fully isothermal solidified zone (ISZ, ∼52 μm wide) consisting of γ-Ni formed at 1100 °C. Concurrently, Cr-Mo borides (∼9.8 GPa) precipitated within the diffusion-affected zone (DAZ) on the Hastelloy X side, becoming the new potential sites for crack initiation. Prolonging the holding time at 1100 °C not only ensured complete isothermal solidification but also promoted Mo diffusion, which improved the plasticity of the Cr-Mo borides and their interfacial bonding with the γ-Ni matrix (∼5.9 GPa). This synergistic optimization resulted in a significant increase in joint shear strength, achieving a maximum value of 587 MPa under the optimal condition of 1100 °C/40 min.