Sintered alumina and AISI 304 stainless steel discs were joined by solid state diffusion bonding using initially a Ti interlayer and a variety of process temperatures and times. Shear tests indicated that the most favourable bonding conditions were 800 oC/60 min and using these same parameters, a second series of experiments using different interlayer constructions was performed in order to test and compare their efficiencies with regard to thermal residual stresses reduction. Results indicated that Ti/Cu was the most efficient combination and a very similar conclusion was reached by Finite Elements simulation of the residual stress field. Finally, metallographic observation of the Al2O3 /Ti interface showed Al diffusion to the metal and the presence of Ti3Al intermetallics, whilst at the Ti/steel interface Fe diffused deeply into the Ti and stabilization of b-Ti followed.
Al2O3; AISI 304 steel; diffusion bonding; residual stresses; mechanical strength; microstructure
