Hierarchical strengthening and toughening design of superalloy joints via a chemically complex intermetallic alloy-modified diffusion bonding strategy

L. Yuan; F. Y. Jiang; Y. J. Du; Y. Z. Yang; J. Gan; P. K. Liu; D. Hao; J. Y. Zhang; J. H. Luan; H. Zhang; J. L. Li; J. T. Xiong; T. Yang

doi:10.1039/d6mh00257a

Hierarchical strengthening and toughening design of superalloy joints via a chemically complex intermetallic alloy-modified diffusion bonding strategy

L. Yuan
, F. Y. Jiang
, Y. J. Du
, Y. Z. Yang
, J. Gan
, P. K. Liu
, D. Hao
, J. Y. Zhang
, J. H. Luan
, H. Zhang
, J. L. Li
, J. T. Xiong
, T. Yang

School of Materials Sience and Engineering

City University of Hong Kong
Shenzhen Research Institute of City University of Hong Kong
Northwestern Polytechnical University Xian
Thermal Power Research Institute
Ltd

Research output: Contribution to journal › Article › peer-review

Abstract

The design and fabrication of advanced interlayer materials are pivotal for the diffusion bonding (DB) of precision and slip-structure turbine components in aero-engines. Here, we developed a chemically complex intermetallic alloy (CCIMA) interlayer exhibiting exceptional mechanical properties at both room and elevated temperatures. Acting as the core of a tailored “BNi-2/CCIMA/BNi-2” sandwich interlayer, the CCIMA plays a critical role in joining powder metallurgy superalloys via the multi-interlayer composite bonding (MICB) strategy. This innovative approach leads to the formation of a robust hetero-structured joint architecture comprising alternating diffusion-affected zones (DAZs), isothermally solidified zones (ISZs), and a central CCIMA region. The CCIMA core, featuring recrystallized L1₂-ordered grains, critically promotes the extensive precipitation of cuboidal L1₂-structured nanoparticles within the ISZs. Under the optimized bonding conditions (1150 °C, 2 h), detrimental Nb–Ta-rich borides in the CCIMA region are completely suppressed, while a high-density (∼57 vol%, ∼367 nm diameter) of L1₂ precipitates forms in the ISZ. The resulting joints achieve an ultimate tensile strength of ∼1325.7 MPa (>93% of the base metal (BM) strength) and elongation of ∼27.7%, which is comparable to the BM's ductility. This outstanding performance is attributed to hierarchical strengthening and toughening mechanisms induced by the CCIMA interlayer, including macroscale strain delocalization enabled by the hetero-structured architecture, microscale dislocation pinning via grain boundaries/serrated bonded interfaces and L1₂ precipitates, and atomic-level bonding enhancement through tailored diffusion control. This study highlights the critical role of CCIMA as a functional interlayer material, establishing a new paradigm for manufacturing/repairing high-performance turbine components in next-generation aero-engines.

Original language	English
Journal	Materials Horizons
DOIs	https://doi.org/10.1039/d6mh00257a
State	Accepted/In press - 2026

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10.1039/d6mh00257a

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Yuan, L., Jiang, F. Y., Du, Y. J., Yang, Y. Z., Gan, J., Liu, P. K., Hao, D., Zhang, J. Y., Luan, J. H., Zhang, H., Li, J. L., Xiong, J. T., & Yang, T. (Accepted/In press). Hierarchical strengthening and toughening design of superalloy joints via a chemically complex intermetallic alloy-modified diffusion bonding strategy. Materials Horizons. https://doi.org/10.1039/d6mh00257a

@article{f503105800494f78b29d56ae7ddfb957,

title = "Hierarchical strengthening and toughening design of superalloy joints via a chemically complex intermetallic alloy-modified diffusion bonding strategy",

abstract = "The design and fabrication of advanced interlayer materials are pivotal for the diffusion bonding (DB) of precision and slip-structure turbine components in aero-engines. Here, we developed a chemically complex intermetallic alloy (CCIMA) interlayer exhibiting exceptional mechanical properties at both room and elevated temperatures. Acting as the core of a tailored “BNi-2/CCIMA/BNi-2” sandwich interlayer, the CCIMA plays a critical role in joining powder metallurgy superalloys via the multi-interlayer composite bonding (MICB) strategy. This innovative approach leads to the formation of a robust hetero-structured joint architecture comprising alternating diffusion-affected zones (DAZs), isothermally solidified zones (ISZs), and a central CCIMA region. The CCIMA core, featuring recrystallized L12-ordered grains, critically promotes the extensive precipitation of cuboidal L12-structured nanoparticles within the ISZs. Under the optimized bonding conditions (1150 °C, 2 h), detrimental Nb–Ta-rich borides in the CCIMA region are completely suppressed, while a high-density (∼57 vol\%, ∼367 nm diameter) of L12 precipitates forms in the ISZ. The resulting joints achieve an ultimate tensile strength of ∼1325.7 MPa (>93\% of the base metal (BM) strength) and elongation of ∼27.7\%, which is comparable to the BM's ductility. This outstanding performance is attributed to hierarchical strengthening and toughening mechanisms induced by the CCIMA interlayer, including macroscale strain delocalization enabled by the hetero-structured architecture, microscale dislocation pinning via grain boundaries/serrated bonded interfaces and L12 precipitates, and atomic-level bonding enhancement through tailored diffusion control. This study highlights the critical role of CCIMA as a functional interlayer material, establishing a new paradigm for manufacturing/repairing high-performance turbine components in next-generation aero-engines.",

author = "L. Yuan and Jiang, \{F. Y.\} and Du, \{Y. J.\} and Yang, \{Y. Z.\} and J. Gan and Liu, \{P. K.\} and D. Hao and Zhang, \{J. Y.\} and Luan, \{J. H.\} and H. Zhang and Li, \{J. L.\} and Xiong, \{J. T.\} and T. Yang",

note = "Publisher Copyright: This journal is {\textcopyright} The Royal Society of Chemistry, 2026",

year = "2026",

doi = "10.1039/d6mh00257a",

language = "英语",

journal = "Materials Horizons",

issn = "2051-6347",

publisher = "Royal Society of Chemistry",

}

TY - JOUR

T1 - Hierarchical strengthening and toughening design of superalloy joints via a chemically complex intermetallic alloy-modified diffusion bonding strategy

AU - Yuan, L.

AU - Jiang, F. Y.

AU - Du, Y. J.

AU - Yang, Y. Z.

AU - Gan, J.

AU - Liu, P. K.

AU - Hao, D.

AU - Zhang, J. Y.

AU - Luan, J. H.

AU - Zhang, H.

AU - Li, J. L.

AU - Xiong, J. T.

AU - Yang, T.

PY - 2026

Y1 - 2026

N2 - The design and fabrication of advanced interlayer materials are pivotal for the diffusion bonding (DB) of precision and slip-structure turbine components in aero-engines. Here, we developed a chemically complex intermetallic alloy (CCIMA) interlayer exhibiting exceptional mechanical properties at both room and elevated temperatures. Acting as the core of a tailored “BNi-2/CCIMA/BNi-2” sandwich interlayer, the CCIMA plays a critical role in joining powder metallurgy superalloys via the multi-interlayer composite bonding (MICB) strategy. This innovative approach leads to the formation of a robust hetero-structured joint architecture comprising alternating diffusion-affected zones (DAZs), isothermally solidified zones (ISZs), and a central CCIMA region. The CCIMA core, featuring recrystallized L12-ordered grains, critically promotes the extensive precipitation of cuboidal L12-structured nanoparticles within the ISZs. Under the optimized bonding conditions (1150 °C, 2 h), detrimental Nb–Ta-rich borides in the CCIMA region are completely suppressed, while a high-density (∼57 vol%, ∼367 nm diameter) of L12 precipitates forms in the ISZ. The resulting joints achieve an ultimate tensile strength of ∼1325.7 MPa (>93% of the base metal (BM) strength) and elongation of ∼27.7%, which is comparable to the BM's ductility. This outstanding performance is attributed to hierarchical strengthening and toughening mechanisms induced by the CCIMA interlayer, including macroscale strain delocalization enabled by the hetero-structured architecture, microscale dislocation pinning via grain boundaries/serrated bonded interfaces and L12 precipitates, and atomic-level bonding enhancement through tailored diffusion control. This study highlights the critical role of CCIMA as a functional interlayer material, establishing a new paradigm for manufacturing/repairing high-performance turbine components in next-generation aero-engines.

AB - The design and fabrication of advanced interlayer materials are pivotal for the diffusion bonding (DB) of precision and slip-structure turbine components in aero-engines. Here, we developed a chemically complex intermetallic alloy (CCIMA) interlayer exhibiting exceptional mechanical properties at both room and elevated temperatures. Acting as the core of a tailored “BNi-2/CCIMA/BNi-2” sandwich interlayer, the CCIMA plays a critical role in joining powder metallurgy superalloys via the multi-interlayer composite bonding (MICB) strategy. This innovative approach leads to the formation of a robust hetero-structured joint architecture comprising alternating diffusion-affected zones (DAZs), isothermally solidified zones (ISZs), and a central CCIMA region. The CCIMA core, featuring recrystallized L12-ordered grains, critically promotes the extensive precipitation of cuboidal L12-structured nanoparticles within the ISZs. Under the optimized bonding conditions (1150 °C, 2 h), detrimental Nb–Ta-rich borides in the CCIMA region are completely suppressed, while a high-density (∼57 vol%, ∼367 nm diameter) of L12 precipitates forms in the ISZ. The resulting joints achieve an ultimate tensile strength of ∼1325.7 MPa (>93% of the base metal (BM) strength) and elongation of ∼27.7%, which is comparable to the BM's ductility. This outstanding performance is attributed to hierarchical strengthening and toughening mechanisms induced by the CCIMA interlayer, including macroscale strain delocalization enabled by the hetero-structured architecture, microscale dislocation pinning via grain boundaries/serrated bonded interfaces and L12 precipitates, and atomic-level bonding enhancement through tailored diffusion control. This study highlights the critical role of CCIMA as a functional interlayer material, establishing a new paradigm for manufacturing/repairing high-performance turbine components in next-generation aero-engines.

UR - https://www.scopus.com/pages/publications/105035730314

U2 - 10.1039/d6mh00257a

DO - 10.1039/d6mh00257a

M3 - 文章

AN - SCOPUS:105035730314

SN - 2051-6347

JO - Materials Horizons

JF - Materials Horizons

ER -

Hierarchical strengthening and toughening design of superalloy joints via a chemically complex intermetallic alloy-modified diffusion bonding strategy

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