Low-temperature direct diffusion bonding of Zr702 alloys via electric current assistance

Integrated zirconium (Zr) alloy fuel claddings require low-temperature and high-efficiency joining technologies for nuclear applications. However, conventional direct-joining technologies make it challenging to satisfy critical requirements at relatively low temperatures in a short time. As a promising alternative, the electric-current-assisted joining (ECAJ) method was studied to reduce the joining temperature and time required for the direct joining process. ECAJ was performed on a spark plasma sintering apparatus, with the specimens assembled with and without graphite dies in the two models. The microstructural evolution and mechanical properties of Zr/Zr joints were investigated at 600 − 900 °C for 1 s to 30 min under a pressure of 30 MPa using different configurations with or without a graphite die. While the joint quality varied with the joining conditions, no significant phase transformation, abnormal grain growth, or preferential orientation was observed at the interface. The maximum shear strength of 404 ± 78 MPa and hardness of 370.9 ± 49.8 HV were achieved at 600 °C for 10 min using a die-less configuration. The joining mechanism was discussed in terms of the potential thermal and electric effects inside the specimen, with the low-temperature joining mechanism attributed to the combined effect of transient overheating and electric-field-accelerated element self-diffusion at the interface, with the latter playing a leading role.