Diffusion Welding
Best Quality Products, Competitive Pricing, Fastest Delivery
Designing and manufacturing diffusion welding products
Precise and accurate assessment and welding
Diffusion welding for a wide range of metals
Large capabilities, strong manpower, and the latest technical and technological support
Tuling: Top Diffusion Welding Product Manufacturer Company in China
Tuling is your one-stop solution for metal stamping and diffusion welding products. We are committed to manufacturing the best-quality diffusion bonding products for our valuable customers worldwide.
We leverage the diffusion welding process through the top-standard diffusion bonding machine, where the latest diffusion bonding technology is used.
We specialize in metal diffusion bonding for a wide range of diffusion bonding of materials. We use different diffusion welding machines for different materials.
We assure you that you will get a total diffusion welding product solution from us of high quality and quantity.
High-Level Technical and Production Capability for Diffusion Welding
At Tuling, we have a high-level capacity for diffusion bonding services for materials. We have a large capacity, the latest technology, and high-end equipment for welding and assembly.
To leverage the process for the materials, we feature the latest diffusion bonding equipment with cutting-edge technology. Since the same diffusion welding machine doesn’t suit all materials, we feature different machines for different materials, including the following.
Metal Diffusion Bonding for Different Materials
Diffusion-bonding copper and aluminum are the most popular and widely used diffusion welding products in different industries. We specialize in them with precise cutting, shaping, sizing, and finishing for different industries.
Aside from these, we manufacture diffusion-bonding stainless steel, diffusion-bonding titanium, and other metal diffusion-bonding products.
Customized Product Through Graphite Tooling
Our diffusion-welded products are made with graphite tooling. The entire graphite tooling system includes fixtures, dies, and supports for proper shaping, pressure, and alignment.
Graphite tooling is high-temperature resistant, has very good thermal conductivity, has very low thermal expansion, and has reduced friction.
Alongside these advanced features, graphite tooling is cost-effective and can easily be machined into complex shapes for customized products. Also, this tooling is non-contaminant, which doesn’t introduce impurities into the weld zone. As a result, the outcome of the diffusion-bonded products is top-notch with desired specifications.
Products
Diffusion-Bonding for Copper Products
Our diffusion-bonding copper products are smooth and electrically conductive. We ensure accurate shape and conductivity with high precision for both solid and flexible busbars.
Diffusion-Bonding for Aluminum Products
Our diffusion-bonding aluminum products have high-fracture toughness, as well as great post-bond alignment. We provide precise quality for both solid and flexible busbars.
Diffusion-Bonding for Stainless Steel Products
Our stainless steel products of diffusion bonding are too precise and very strong. We guarantee top-level craftsmanship that ensures no deformation of the products.
Diffusion Bonding for Titanium Products
Our diffusion-bonding titanium products are so generous and resistant to contamination. They are mostly used in the aerospace industry.
Diffusion Welding for Nickel-Based Alloy Products
We ensure smooth and strong nickel-based alloy products with accurate shapes and alignment. They are welded with complex designs with corrosion and oxidation resistance.
Diffusion Welding for Tungsten Products
They are resilient to high temperatures. With accurate shape and finish, we ensure diffusion welding for tungsten products for different industries.
Customized Process
We leverage customized diffusion bonding for copper and aluminum materials. We make very thin copper, aluminum, etc., strips from raw materials. After getting the strips, we go through die cutting and blanking to determine the desired dimension and shape.
After making the raw shapes of thin strips for the diffusion bond products (mainly busbars and others), we implement the bonding stage in a well-controlled environment where graphite tooling and hydraulic pressure are applied.
After the diffusion bonding of materials, we go through the subsequent multi-step process for the final production.
Diffusion Welding FAQs
Diffusion bonding or diffusion welding is the solution for welding two materials without keeping any mark of welding. When you diffusion bond two materials, no microstructure will be created in the bond line.
Rather, the bonded line becomes almost similar to the parent materials. In diffusion welding, you don’t need any filler materials for bonding. With so many great features, you may ask what diffusion bonding actually is,
Let’s answer some relevant questions about diffusion bonding, which will help you to get insight into this bonding process.
What is Diffusion Welding?
Diffusion bonding, or diffusion bonding, is a solid-state welding technology for bonding metals and plastics. The pressure and below-melting-point (50% to 90%) temperature of parent materials are the two main parameters used for diffusion bonding.
Can diffusion bonding join a metal and a non-metal?
No, diffusion bonding isn’t used to join metal to non-metal materials. This is because the atomic characteristics of metals and non-metals are different. Metals create metallic bonds, and non-metals generally form covalent bonds, which are different.
What temperature does copper diffusion bond?
The diffusion bonding temperature of the metals ranges from 50% to 90% of the melting temperature of the parent material. For copper, the diffusion starts at 500° and higher since its melting temperature is 1084°C. It can be lower or higher based on the bonding environment.
Is it possible to join two dissimilar metals by diffusion bonding?
Yes, diffusion bonding is possible for both similar and dissimilar metals. Diffusion welding is also the most effective and reliable way to bond dissimilar metals.
What is the thickness of copper foil for diffusion bonding?
The thickness of copper foil sheets can be 0.025 mm to 0.25 mm. We basically use 0.1 mm thick copper foil sheets for our copper busbars.
What temperature does aluminum diffusion bond?
The range for diffusion bonding temperature of aluminum alloy is 482°C to 535°C. However, the most preferred diffusion temperature is 516°C most of the time.
What is a gas diffuser in welding?
In the gas diffusion welding process, metal inert gas(MIG) is used to create pressure on the welded materials. MIG welding gas diffuser ensures the even distribution of the inert gas across the bonded surfaces of the bonding materials.
What are solid or rigid busbars?
Solid or rigid busbars are solid metal bars made of highly current conductive materials, basically copper and aluminum. They transport electric current with minimal energy loss and better heat dissipation. They are used in electrical and energy sectors like transformers, high voltage EV batteries, circuit breakers, heat sinks, etc.
What are soft or flexible busbars?
Flexible busbars are electrical conductors made in a state of flexibility to install in tighter spaces for electric conductivity. They are the same electric current conductors as solid busbars but are not flexible in structure.
They are designed to be bent or twisted yet keep their functionalities where the application area is limited or complex. They are made of multiple thin layers of copper or aluminum with PVC insulating jackets.
What is vacuum diffusion bonding?
In vacuum diffusion bonding, hydraulic or mechanical pressure is applied to join metals in a vacuum chamber. Steel, copper, aluminum, etc., are mainly pressed in vacuum diffusion bonding machines.
What is graphite tooling in diffusion bonding?
Graphite tooling is a specialized fixture in a vacuum furnace diffusion welding machine that precisely holds the metal workpieces that are to be diffusion bonded throughout the entire bonding process.
This works within the chamber diffusion chamber. Tooling doesn’t control environmental factors like temperature and pressure.
What is the chamber in a diffusion bonding machine?
The chamber of a diffusion machine is the enclosed space where the diffusion bonding process takes place. This is the controlled environment of the bonding process with precise temperature and pressure.
Generally, diffusion bonding chambers are categorized into two main types: vacuum furnaces and hot presses.
How many stages are required for solid-state diffusion bonding?
In the diffusion welding process, the bonding materials go through two stages. In The first stage, precise pressure is applied for smooth contact of the surfaces of the workpieces.
In the second stage, precise heat is applied for the final bonding process within a certain time frame.
How do diffusion bonding and laser welding differ?
Diffusion bonding uses hgh pressure, and high-heat for welding. On the other hand, laser welding uses concentrated laser beams to melt the joining line of the to-be-joined materials.
The laser beam creates a molten pool in the joint zone, and then solidifies the molten pool to create the bonding.
Are ultrasonic metal welding and diffusion welding the same?
No, ultrasonic metal welding and diffusion welding are two different technologies, though they create solid-state bonding.
Where diffusion welding is done by applying pressure, and heat, ultrasonic welding uses high-frequency vibration, and friction to create the bonding between the metals.
How are diffusion bonding and brazing different?
Brazing is also a technique to bond metals like diffusion welding. But brazing uses liquid filler between the joining workpieces by melting the filler, and disperse it across the joining line. Contrarily, diffusion bonding doesn’t use any filler material.
How do pressure and temperature impact the diffusion welding process?
More pressure, and higher temperature increase the bonding rate. Particularly higher temperature can increase the bonding rate so much where it can change the required processing time from hours to minutes.
How long does it take to complete a diffusion bonding product manufacturing?
It actually depends on the order size, product design types, and the particular product categories. After the assessment of every related thing, the diffusion bonding service provider can estimate the time.
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