Electric field suppresses intermetallics via enhanced diffusion and non-equilibrium phase transformation solid solution in ultrafast brazed Ti2AlNb/Ti60 joints

doi:10.1016/j.jmst.2025.12.061

Abstract

Abstract: Conventional brazing requires prolonged heating to form joints, which often results in a continuous brittle intermetallic layer that can initiate microcracks. Moreover, heating the entire workpiece induces substantial thermal stress and deformation, leading to detrimental residual stresses that impair joint performance. To address these limitations, this study adopts electric field-assisted brazing (EFAB), which utilizes pulsed electric current to generate Joule heating and electromigration effects, enabling rapid and efficient bonding at shorter processing times. EFAB was developed to join Ti₂AlNb and Ti60 alloys at 900 °C within < 1 s using a Ti-Zr-Ni-Cu-Co-Nb amorphous filler under 150 V/135 A/mm². Compared to conventional brazing (15 min dwell), EFAB eliminates brittle (Ti, Zr)₂(Cu, Ni) intermetallics through a uniform distribution of brittle elements driven by electromigration and concentration gradients, forming defect-free brazing seams comprising α-Ti + α′-Ti martensite (Ti60 side), α′-Ti martensite (brazing center), and α + β duplex (Ti₂AlNb side). Finite element simulations confirm EFAB reduces residual stress by 83 % via rapid Joule heating and α′-twinning. Interfacial electronic analysis reveals that the α-Ti/β-Ti interface exhibits remarkable charge accumulation and symmetric decay in differential charge density profiles, along with continuous transitions and robust orbital hybridization in the projected density of states. Additionally, it demonstrates an 8.7 % enhancement in separation work, with values reaching 0.3393 eV/Å² compared to 0.3123 eV/Å² (Ti₂Cu/α-Ti). These properties enable a semi-coherent α-Ti/β-Ti interface (22.4 % mismatch) versus incoherent Ti₂Cu/α-Ti (58.6 %). Consequently, EFAB joints achieve 221.9 MPa shear strength (30 % higher than conventional joints) with ductile fracture, demonstrating high-efficiency dissimilar joining of advanced titanium alloys.

Key words: Brazed joint, Electric field-assisted, Microstructure optimization, Residual stress relief, First-principles calculations

Peng Wang, Haiyan Chen, Zhaoyi Pan, Heng Shao, Jiabao Xiang, Shuai Zhao, Pengcheng Wang, Wenya Li. Electric field suppresses intermetallics via enhanced diffusion and non-equilibrium phase transformation solid solution in ultrafast brazed Ti₂AlNb/Ti60 joints[J]. J. Mater. Sci. Technol., 2026, 270: 95-111.

References

[1] D. Banerjee, Prog. Mater. Sci. 42(1997) 135-158.
[2] L.C. Zhang, L.Y. Chen, L. Wang, Adv. Eng. Mater. 22(2020) 1901258.
[3] H. Zhang, N. Yan, H. Liang, Y. Liu, J. Mater. Sci.Technol. 80(2021) 203-216.
[4] J. Jia, W. Sun, W. Peng, Z. Yang, Y. Xu, X.X. Zhong, W. Liu, J. Luo, Adv. Powder Technol. 31(2020) 1963-1974.
[5] X. Li, G. Wang, J. Zhang, Y. Liu, Int. J. Adv. Manuf. Technol. 106(2020) 77-89.
[6] Y.J. Li, A.P. Wu, Q. Li, Y. Zhao, R. Zhu, G. Wang, Trans. Nonferrous Met. Soc. China. 29(2019) 1873-1881.
[7] P. Lin, T.T. Tang, C.Z. Chi, S.Z. Zhang, C.J. Zhang, Rare Met. Mater. Eng. 47(2018) 416-422.
[8] K. Han, L. Tan, C. Yao, D. Zhang, Z. Zhou, J. Manuf. Process. 76(2022) 349-364.
[9] W. Li, Z. Chen, J. Liu, S. Zhu, G. Sui, Q. Wang, J. Mater. Sci.Technol. 35(2019) 790-798.
[10] R.C. Jia, W.D. Zeng, S.T. He, X.X. Gao, J.W. Xu, J. Alloy. Compd. 810(2019) 151899.
[11] W. Peng, W. Zeng, Q. Wang, H. Yu, Mater. Sci. Eng. A 571 (2013) 116-122.
[12] X. Nai, H.Y. Chen, S. Zhao, X.W. Kong, Q. Wang, P.C. Wang, W.Y. Li, Mater. Sci. Eng. A 877 (2023) 145190.
[13] Z.G. Guo, T.J. Ma, X. Chen, X.W. Yang, J. Tao, J. Li, W.Y. Li, A. Vairis, J. Mater. Res.Technol. 24(2023) 5660-5668.
[14] C. Cheng, B. Yu, Z. Chen, J. Liu, Q.J. Wang, J. Mater. Sci.Technol. 34(2018) 1859-1866.
[15] L. Li, L. Sun, M. Li, J. Mater. Res.Technol. 17(2022) 1274-1288.
[16] S. Zhao, X. Nai, H.Y. Chen, P. Wang, Q. Wang, Y.S. Liu, P.C. Wang, W.Y. Li, Mater. Sci. Eng. A 891 (2023) 145914.
[17] S. Zhao, B.Q. Shao, H.Y. Chen, Y.Q. Hu, Z.Y. Pan, Y.C. Liu, P.C. Wang, X.G. Song, W.Y. Li, J. Mater. Sci.Technol. 233(2025) 223-238.
[18] P.C. Wang, W.T. Shi, L. Gu, H. Ran, Z.Y. Pan, Y. Su, X.G. Song, J. Cao, H.Y. Chen, W.Y. Li, J. Mater. Sci.Technol. 244(2026) 46-59.
[19] X. Nai, H.B. Zhang, S. Zhao, P. Wang, H.Y. Chen, P.C. Wang, A. Vairis, W.Y. Li, J. Mater. Process.Technol. 331(2024) 118530.
[20] W.H. Liu, P.C. Wang, W.T. Shi, S. Zhao, X. Nai, X.G. Song, H.Y. Chen, W.Y. Li, Addit. Manuf. 89(2024) 104258.
[21] S.P. Hu, T.Y. Hu, Y.Z. Lei, X.G. Song, D. Liu, J. Cao, D.Y. Tang, Vacuum 152 (2018) 340-346.
[22] Z. Sun, X.X. Zhu, H.Z. Chen, L.X. Zhang, Mater. Charact. 186(2022) 111814.
[23] X.G. Song, B. Ben, S. Hu, J. Feng, D. Tang, J. Alloy. Compd. 692(2017) 485-491.
[24] C.W. Wang, W.W. Ping, Q. Bai, H.C. Cui, R. Hensleigh, R.L. Wang, A.H. Brozena, Z.P. Xu, J.Q. Dai, Y. Pei, C.L. Zheng, G. Pastel, J.L. Gao, X.Z. Wang, H. Wang, J.C. Zhao, B. Yang, X.Y. Zheng, J. Luo, Y.F. Mo, B. Dunn, L.B. Hu, Science 368 (2020) 521-526.
[25] R.F. Guo, H.R. Mao, Z.T. Zhao, P. Shen, Scr. Mater. 193(2021) 103-107.
[26] L. Zhou, C. Li, C. Zhang, M. Zheng, X. Si, J. Qi, J. Cao, J. Eur. Ceram.Soc. 44(2024) 3767-3776.
[27] L. Zhou, C. Li, X. Si, C. Zhang, J. Qi, J. Cao, J. Eur. Ceram.Soc. 43(2023) 7708-7713.
[28] P. Wang, S. Zhao, X. Nai, H. Chen, P.C. Wang, X.G. Song, W.Y. Li, Mater. Sci. Eng. A 909 (2024) 146856.
[29] V. Wang, N. Xu, J.C. Liu, G. Tang, W.T. Geng, Comput. Phys. Commun. 267(2021) 108033.
[30] J. Li, Y. Yang, G. Feng, X. Luo, Q. Sun, N. Jin, Appl. Surf. Sci. 286(2013) 240-248.
[31] L. Liu, S. Wang, H. Ye, J. Mater. Sci.Technol. 19(2003) 540-544.
[32] P.C. Wen, L.J. Yuan, R. Tao, J. Li, D. Li, Appl. Surf. Sci. 604(2022) 154535.
[33] J.P. Perdew, K. Burke, M. Ernzerhof, Phys. Rev. Lett. 77(1996) 3865.
[34] J. Hafner, J. Comput. Chem. 29(2008) 2044-2078.
[35] P.E. Blöchl, Phys. Rev. B 50 (1994) 17953.
[36] S. Grimme, J. Comput. Chem. 27(2006) 1787-1799.
[37] H.J. Monkhorst, J.D. Pack, Phys. Rev. B 13 (1976) 5188.
[38] H. Berns, V. Gavriljuk, Key Eng. Mater. 345(2007) 421-424.
[39] J.J. Burton, A.S.Nowick, in: Diffusion in Solids: Recent Developments, Academic Press, New York, 1975, pp. 303-352.
[40] Y. Li, Y. Yang, X. Feng, J. Mater. Sci.Technol. 24(2008) 410-414.
[41] H. Guo, M. Rao, J. Zhang, X. Wang, G. Luo, Q. Shen, J. Mater. Process.Technol. 315(2023) 117933.
[42] T. Zhang, D. Wei, E. Lu, W. Wang, K. Wang, X. Li, L.C. Zhang, H. Kato, W. Lu, L. Wang, J. Mater. Sci.Technol. 131(2022) 68-81.
[43] N. Derimow, J.T. Benzing, H. Joress, A. McDannald, P. Lu, F.W.DelRio, N. Moser, M.J. Connolly, A. Savillea, O. Kafkaa, C. Beamerd, R. Fishele, S. Sarkerf, C. Hadleyg, N. Hrabea, Mater. Des. 247(2024) 113388.
[44] Y. Qi, L.G. Hector Jr., Phys. Rev. B 69 (2004) 235401.
[45] W. Sun, L. Zhang, X. Huang, J. Liu, H. Wang, Y. Bu, Comput. Mater. Sci. 136(2017) 157-162.
[46] S.V. Dudiy, B.I. Lundqvist, Phys. Rev. B 69 (2004) 125421.
[47] H. Padmanabhan, M.S.Ramachandra Rao, B.R.K. Nanda, in: Proceedings of the 59th DAE Solid State Physics Symposium 2014, Tamilnadu, India, 2014.
[48] Y.Z. Liu, Z.L. Shi, Y.B. Zhang, M. Qin, S.P. Hu, X.G. Song, W. Fu, B.J. Lee, J. Mater. Sci.Technol. 203(2024) 126-142.
[49] S. Shu, X. Chen, Y. Wei, S. Xie, S. Zhang, F. Qiu, Q. Jiang, J. Mater. Res.Technol. 30(2024) 2500-2507.
[50] J. Ding, A. Inoue, S.L. Zhu, S.L. Wu, E. Shalaan, A.A.Al-Ghamdi, J.Mater. Res. Technol. 15(2021) 5452-5465.
[51] F. Sun, J. Li, H. Kou, B. Tang, Y. Chen, H. Chang, J. Cai, J. Alloy. Compd. 576(2013) 108-113.
[52] J.W. Sim, J.H. Kim, H.P. Chan, J.K. Hong, J.T. Yeom, W.L. Sang, J. Alloy. Compd. 926(2022) 166823.
[53] K. Goyal, N. Sardana, J. Phys. Chem. Solids 179 (2023) 111362.
[54] Y. Yan, J. Lin, K. Huang, X. Zheng, L. Qiao, S. Liu, J. Cao, S.C. Jun, Y. Yamauchi, J. Qi, J. Am. Chem.Soc. 44(2023) 24218-24229.
[55] D. Toprek, J. Belosevic-Cavor, V. Koteski, J. Phys. Chem. Solids 85 (2015) 197-205.

Electric field suppresses intermetallics via enhanced diffusion and non-equilibrium phase transformation solid solution in ultrafast brazed Ti₂AlNb/Ti60 joints

PDF (PC)

Knowledge

Abstract

Cite this article

share this article

References

Related Articles 15

Recommended Articles

Metrics

Comments

[1]	Yuxuan Wang, Guoqiang Lan, Jun Song. Quantitative thermal conductivity prediction based on supercell phonon-unfolding for high-entropy ceramic oxides [J]. J. Mater. Sci. Technol., 2026, 256(0): 166-177.
[2]	Enhao Liu, Xiaochun Wang, Jinzhou Li, Chao Chen, Qian Li, Xuewei Lv, Jie Dang. Two-dimensional lamellar TiO₂ surface-loaded RuCo nanoclusters for pH-universal electrocatalytic hydrogen evolution [J]. J. Mater. Sci. Technol., 2026, 254(0): 71-80.
[3]	Yuguo Sun, Yuanxu Zhu, Guanlin Lyv, Kai Wang, Panpan Gao, Ping Qian. First-principles study of the effect of solute co-segregation on Y {10 $\bar{1}$1} twin boundary [J]. J. Mater. Sci. Technol., 2026, 249(0): 109-119.
[4]	Zhilin Shi, Xueqing Zhang, Haoran Zhang, Peng Tang, Shunxing Liang, Xinyu Zhang, Mingzhen Ma, Riping Liu. Physical mechanisms behind the different doping strengthening effects of metalloid and non-metallic elements on high-entropy alloys: Taking boron and carbon as examples [J]. J. Mater. Sci. Technol., 2026, 242(0): 41-51.
[5]	K.W. Kang, A.X. Li, B.R. Zhang, J.S. Zhang, M.K. Xu, D. Huang, S.K. Liu, Y.T. Jiang, G. Li. Fabrication of non-equiatomic CoCrFeNi₂ HEAs with exceptional strength and corrosion resistance [J]. J. Mater. Sci. Technol., 2026, 240(0): 166-181.
[6]	Yong Fan, Yuyao Chen, Jin Wang, Lei Gu, Kaixuan Zhou, Yuanyuan Gong, Wei Liu, Yonghao Zhao, Xiangfa Liu, Jinfeng Nie. Insights into crystal growth and morphology evolution mechanism of multi-component carbide: Experiments and first-principles calculations [J]. J. Mater. Sci. Technol., 2026, 240(0): 27-34.
[7]	Chen Liu, Chao Li, Jie Wei, Xin Wei, Changgang Wang, Junhua Dong, Xing-Qiu Chen. First-principles investigation of H⁺/Cl^--mediated electrochemical reduction of β-FeOOH under coastal atmospheric conditions [J]. J. Mater. Sci. Technol., 2026, 267(0): 237-248.
[8]	Jiang Yiming, Li Shuai, Wu Jiahao, Bao Zebin, Wang Jiemin, Zhu Shenglong, Wang Fuhui. Thermodynamic and kinetic stability of pre-grown Al₂O₃ scale under corrosive conditions at 900 °C: Defects, diffusion, surface chemistry, and failure [J]. J. Mater. Sci. Technol., 2026, 266(0): 297-315.
[9]	Jiantao Wang, Yi-Chi Zhang, Yan Liu, Hongkun Deng, Mingfeng Liu, Yan Sun, Bing Li, Xing-Qiu Chen, Peitao Liu. Atomistic mechanisms of phase transitions in all-temperature barocaloric material KPF₆ [J]. J. Mater. Sci. Technol., 2026, 263(0): 211-219.
[10]	Yuchen Liu, Yu Zhou, Dechang Jia, Zhihua Yang, Daxin Li, Wenxian Li, Bin Liu. Insight into the aluminum dopant-induced structure and mechanical property variation in amorphous SiBCN ceramics [J]. J. Mater. Sci. Technol., 2025, 239(0): 161-171.
[11]	Yiming Jiang, Shuai Li, Di Huang, Zebin Bao, Jiemin Wang, Shenglong Zhu, Fuhui Wang. Unveiling corrosion reaction mechanism of β-NiAl coating modified by platinum and hafnium in NaCl- or Na₂SO₄-containing mediums [J]. J. Mater. Sci. Technol., 2025, 237(0): 54-67.
[12]	Shuai Zhao, Buqiu Shao, Haiyan Chen, Yuqi Hu, Zhaoyi Pan, Yongsheng Liu, Pengcheng Wang, Xiaoguo Song, Wenya Li. Wetting and interfacial behavior of high entropy alloy filler on rare earth silicate system: Phase analysis and first-principles calculations [J]. J. Mater. Sci. Technol., 2025, 233(0): 223-238.
[13]	Haoyang Yu, Wei Fang, Tiexu Peng, Chang Liu, Hongxian Xie, Bin Gan, Xin Zhang, Jia Li, Fuxing Yin. Unexpected Young's modulus dependence of refractory solute diffusion in NiCoFeCr-based high entropy alloys [J]. J. Mater. Sci. Technol., 2025, 230(0): 270-281.
[14]	Qingzhong Gui, Wei Yu, Chunmin Cheng, Hailing Guo, Xiaoming Zha, Ruyue Cao, Hongxia Zhong, John Robertson, Sheng Liu, Zhaofu Zhang, Zhuo Jiang, Yuzheng Guo. Origin of two-dimensional hole gas at the hydrogen-terminated diamond surfaces: Negative interface valence-induced upward band bending [J]. J. Mater. Sci. Technol., 2025, 207(0): 76-85.
[15]	Yong Fan, Jinfeng Nie, Zhigang Ding, Yujing Zhang, Xiang Chen, Wei Liu, Sen Yang, Sida Liu, Xiangfa Liu, Yonghao Zhao. A facile high-efficiency preparation strategy for Al-containing multi-component boride microcrystals with superior comprehensive performance [J]. J. Mater. Sci. Technol., 2025, 204(0): 190-203.