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Fail-safe diffusion-bonded printed circuit heat exchangers (PCHE) with integrated leak detection system

Diffusion Bonding Sapphire to Inconel 625, Titanium, Aluminium and Stainless Steel

Sapphire to Ti No 11.png
Sapphire bonded to Titanium frame withstood 120 bars of internal hydraulic pressure before cracking. 

Applications: Inspection windows for ITER & Tokamak Fusion Reactors

Solid-State Diffusion Bonding
Aluminium to Stainless Steel in Air

CJT website bonding in air.png
Amir in Wallwork.jpeg
Courtesy of Wallworks, UK
Amir Wallwork.jpeg
Courtesy of Atlas Technologies - USA
Courtesy of Wallworks, UK
Joining Aluminum Magnesium Alloys

Al-6%Mg (5000 series) diffusion bonded to stainless steel
One of the most difficult combinations of structural alloys to join

Dr Amir Shirzadi (The Open University)
ChengCong Zhang (Wuhan University of Science and Technology)

diffusion bonded tungsten carbide stainless steel
Diffusion Bonding
Tungsten Carbide to Stainless Steel
Thermal Shock Resistant
Diffusion Bonding Aluminum

Joining High Temperature Thermoelectrics (300 to 500°C)


Electrically & Thermally Conductive Joints with Shock-resistant Diffusion Barrier to Protect Skutterutide  

High Temperature Thermoelectric


Laminated Object Manufacturing (LOM) 


Ultra-high pressure laminated aluminium heat exchangers for jet engines


Fuel Oil Heat Exchangers (FOHE) are critical components of modern jet engines. Their primary function is to cool the hot engine lubrication oil while heating the cold fuel coming from the fuel tank before it enters the combustion chamber. The fuel heating increases the engine efficiency substantially by recuperating the waste heat from the oil into the fuel. The fuel/oil pressures and temperatures required are increasing with the development of more efficient jet engines. "Gallium-Assisted Diffusion Bonding" is used to join stacks of aluminium plates containing fluid flow channels; without the weaknesses and limitations inherent in traditional brazing. The article describes a new technology for manufacturing more efficient and lighter Fuel/Oil Heat Exchangers than conventional shell and tube ones.

Presentation by Dr Amir Shirzadi


International Congress and Exhibition on Aluminium Heat Exchanger Technologies for HVAC&R 2019

07 – 08 May, 2019 Düsseldorf/Germany

Diffusion Bonded Heat Exchangers Used in Jet Engines & Oil & Gas Reformers
Aluminium / Stainless Steel / Superalloy


Laminated Object Manufacturing (LOM) - Multilayer Heat Exchangers
Laminated Aluminium Heat Exchanger (FOHE)
Maximum channel pressure ~ 16,000 PSI
(based on 2222 kg tensile strength)
Laminated Aluminium Heat Exchanger
High temperature heat exchanger
Inconel micro-channel reformer
(tensile tested)
Laminated aluminium heat exchangers, 
high temperature Inconel reformer, and stainless steel micro-channel medical device have tensile strengths comparable to those of the corresponding parent alloys.
Bonding Sapphire to Aluminium Titanium Steel

Hybrid Non-Magnetic Hermetic Bellow

Titanium bellow, made by TIG welding process, has been diffusion bonded to an aluminium tube leading to a fully hermetic seal.

Aluminium Titanium Bellow
Diffusion Bonding Titanium to Stainless Steel funded by UK Research and Innovation
Diffusion Bonding of Titanium to Stainless Steel: 313 MPa Tensile Strength
Funded by UK Research and Innovation based on patented process by Amir Shirzadi
Welding Titanium to Steel
Bimetal Flanges & Couplers 
Steel Titanium Aluminium Flanges
 Al / Ti                                                        Al / Steel
Aluminium Titanium Adaptor
 Al / Ti
High precision Bonding
Bonding Similar & Dissimilar Titanium Alloys
High Precision
Diffusion Bonding of 
Satellite Components
Miniature turbine with 0.5 mm tall blades
fabricated by diffusion bonding
(+/-10 Microns)  
Diffsion Bonding Titanium
Our Proprietary Solutions

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Main Team Members
Amir Shirzadi - Diffusion Bonding and Weld Alloy Design

Amir Shirzadi
Diffusion Bonding

& Weld Alloy Design

Hamid Assadi

Hamid Assadi
Microstructure Simulation

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