FeCrAl and Zr alloys joined using hot isostatic pressing for fusion energy applications

FeCrAl and Zr alloys were joined by a hot isostatic pressing (HIP) method for fusion energy applications. The optimum conditions for the joining process were studied. The HIP temperatures were varied from 700 to 1050 °C. The mechanical properties of the HIPed samples were evaluated by four-point bending and tensile tests. The FeCrAl and Zr alloys HIPed at 700 °C showed higher joint strength than the other samples. The joint strength decreased with an increase in the HIP temperature from 700 to 950 °C and significantly dropped at 1050 °C. Transmission electron microscopy, scanning electron microscopy, and optical microscopy were used to characterize the joints and interface region of the HIPed samples. The joints appeared to be tightly bonded and no intermetallic compounds or gaps were observed at the interface for HIP temperatures up to 950 °C. A diffusion layer formed at the interface and its thickness increased with the HIP temperature. HIP at 1050 °C, on the other hand, resulted in significant inter-diffusion and formation of brittle inter-metallic compounds at the interface.