Metallurgical and Materials Transactions A

, Volume 44, Supplement 1, pp 154–161 | Cite as

Optimizing the Diffusion Welding Process for Alloy 800H: Thermodynamic, Diffusion Modeling, and Experimental Work

  • Ronald E. Mizia
  • Denis E. Clark
  • Michael V. GlazoffEmail author
  • Tedd E. Lister
  • Tammy L. Trowbridge


A research effort was made to evaluate the usefulness of modern thermodynamic and diffusion computational tools, Thermo-Calc and Dictra (Thermo_Calc Software, Inc., McMurray, PA), in optimizing the parameters for diffusion welding of Alloy 800H. This would achieve a substantial reduction in the overall number of experiments required to achieve optimal welding and post-weld heat treatment conditions. This problem is important because diffusion-welded components of Alloy 800H are being evaluated for use in assembling compact, micro-channel heat exchangers that are being proposed in the design of a high-temperature, gas-cooled reactor by the U.S. Department of Energy. The modeling was done in close contact with experimental work. The latter included using the Gleeble 3500 System (Dynamic Systems, Inc., Poestenkill, NY) for welding simulation, mechanical property measurement, and light optical and scanning electron microscopy. The modeling efforts suggested a temperature of 1423 K (1150 °C) for 1 hour with an applied pressure of 5 MPa using a 15-μm Ni foil as joint filler to reduce chromium oxidation on the welded surfaces. Good agreement between modeled and experimentally determined concentration gradients was achieved, and model refinements to account for the complexity of actual alloy materials are suggested.


Welding Diffusion Couple Filler Metal Sigma Phase Weld Interface 
These keywords were added by machine and not by the authors. This process is experimental and the keywords may be updated as the learning algorithm improves.



The authors would like to express gratitude to the Next Generation Nuclear Plant (NGNP) Program Management (Messrs Michael Patterson and Charles Park) at INL for their continuous support of this research effort. The work was supported through the U.S. Department of Energy, Office of Nuclear Energy, Science, and Technology, under DOE Idaho Operations Office Contract DE-AC0799ID13727. The authors would like to acknowledge Todd Morris for metallurgical support. One of the authors (M.V.G.) would like to extend his most sincere gratitude to Dr. Carolyn Campbell (NIST) for her generous support of our initial modeling efforts. We are also very grateful to Prof. Zi-Kui Liu and Prof. Long-Qing Chen (both of Penn State University) for the valuable discussions, and to Prof. John E. Morral (of Ohio State University) for the useful discussion of the obtained results.

This submitted manuscript was authored by a contractor of the U.S. Government under DOE Contract No. DE-AC07-05ID14517. Accordingly, the U.S. Government retains and the publisher, by accepting the article for publication, acknowledges that the U.S. Government retains a nonexclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this manuscript, or allow others to do so, for U.S. Government purposes.

U.S. Department of Energy Disclaimer

This information was prepared as an account of work sponsored by an agency of the U.S. Government. Neither the U.S. Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. References herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise, does not necessarily constitute or imply its endorsement, recommendation, or favoring by the U.S. Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the U.S. Government or any agency thereof.


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Copyright information

© The Minerals, Metals & Materials Society and ASM International 2011

Authors and Affiliations

  • Ronald E. Mizia
    • 1
  • Denis E. Clark
    • 1
  • Michael V. Glazoff
    • 2
    Email author
  • Tedd E. Lister
    • 1
  • Tammy L. Trowbridge
    • 1
  1. 1.Materials Science DivisionIdaho National LaboratoryIdaho FallsUSA
  2. 2.Advanced Process and Decision Systems DivisionIdaho National LaboratoryIdaho FallsUSA

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