Latest  Developments

Component Made of Aluminium Powder by Diffusion Bonding 

Courtesy of Dr Amir Shirzadi: The Open University (Space Science and Exploration)

Joining High Temperature Thermoelectrics (300 to 500°C)

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

Diffusion Bonding Aluminium to Steel & Titanium 

Bond tensile strengths exceeded the ultimate strength of aluminium

Laminated Object Manufacturing (LOM) 

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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.

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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

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Maximum channel pressure ~ 16,000 PSI

(based on 2222 kg tensile strength)

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.

Diffusion Bonding Sapphire to Aluminum / Titanium

Optical Devices

Bimetal Flanges & Couplers 

 Al / Ti                                                        Al / Steel

 Al / Ti

Bonding Similar & Dissimilar Titanium Alloys

High Precision
Diffusion Bonding of 

Satellite Components

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Miniature turbine with 0.5 mm tall blades

fabricated by diffusion bonding

(+/-10 Microns)  

Microstructure Simulation

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