Two-step transient liquid phase bonding of NiTi to Ti-6Al-4V through a NbZrW barrier
Dissimilar joining of NiTi to Ti-6Al-4V (Ti-64) is limited by brittle Ti2Ni formation and degradation of NiTi functionality. A two-step transient liquid phase (TLP) route was developed in which a refractory NbZrW diffusion barrier converts the incompatible couple into two independently bondable interfaces. The barrier plays a different role for each alloy: a reactive substrate for NiTi, dissolving to form a Ti-rich Ni-Ti-Nb liquid that infiltrates its own grain boundaries and is terminated by selective Ti absorption into the barrier; and an inert substrate for Ti-64, joined through contact melting of a sacrificial Cu foil. Both interfaces are fully dense and free of continuous intermetallic layers. In tension, joints spanning both interfaces began transforming at 350 MPa, exhibited a stress plateau to 2.5 global strain (consistent with stress-induced transformation of the NiTi half of the gauge) and failed beyond the plateau at 380-410 MPa. Five load-unload cycles to 460 MPa showed stable superelastic loops with minor ratcheting. These results demonstrate that a diffusion barrier enables dissimilar TLP joining of otherwise incompatible alloys.