Diffusion bonding is a well-researched joining process whose outstanding possibilities for the joining (technical) quality of workpieces are increasingly coming to the fore.
This process is predestined above all for flat components that have to meet the highest demands for strength and corrosion resistance. Diffusion bonding does not require any filler materials. Consequently, the process can be regarded as "non-toxic" from the point of view of potential cross-contamination, and no costly post-cleaning of the components is required. Welded joints are produced which can no longer be distinguished optically and microscopically from the base materials.
In the production of injection molds, diffusion bonding opens up new design and strength possibilities. The optimized method of mold cooling leads to shorter cycle times for injection molding equipment.
In components for photolithographic structuring and thin-film production equipment, the joints meet the highest demands for corrosion resistance and long service life. Downtimes due to failures can be reduced to a minimum. In addition, there are no undesirable elements in the joining zone that could cause contamination of the equipment. In addition to high-quality steel joints, aluminum and its alloys can also be welded.
Diffusion-welded heat exchangers made of steels or nickel-based alloys are manufactured for extreme process temperatures and pressures (-200 -600°C and pressures up to 1000bar) due to the joint strength. These heat exchangers, known as PCHEs, are mainly used in gas liquefaction and at hydrogen tapping points.
In the field of electromobility, copper or aluminum components are increasingly used for thermal management and electrical contacting, which often pose a challenge in terms of joining technology Flat copper and/or aluminum welds are predestined for diffusion bonding.
PVA TePla AG, the process and plant engineering specialist, has recognized the potential of the process for a range of applications and has appointed diffusion bonding as a key strategic technology.
In cooperation with customers, in-house process and equipment developers, robust processes for stainless steel, tool steel, copper and aluminum components have been developed and are offered as a service.
Due to the strong increase in demand, capacity in this area will be expanded by a second plant of comparable size (800 x 800 mm² press area) starting in Q1 2021. In addition to toolmaking for plastic injection molding and medical technology companies dealing with high-performance heat exchangers, the current customer base primarily includes players in the semiconductor industry.
Traditionally, diffusion bonding also offers many opportunities in the aerospace sector. The future markets of electric and hydrogen mobility are also gradually gaining in importance.
Europe's largest competence and service center for diffusion bonding with a focus on industrial introduction and production is being created.
PVA TePla AG uses its many years of expertise to develop diffusion bonding systems whose pressing principle allows high pressures to be generated homogeneously over a very large area (up to 1.5 m²).
With its many years of experience, the sister company PVA Industrial Vacuum Systems ensures precisely fitting and efficient furnaces. Vacuum Processing Service - in cooperation with research institutes - is particularly involved in the development, design and optimization of diffusion bonding processes.
The ”Günther Köhler Institute for Joining Technology and Materials Testing” (ifw) in Jena has been a reliable partner for many years.