- Email: [email protected]
A Finite Element Analysis of Dissimilar Materials Diffusion Bonded Joints
Available online at www.sciencedirect.com
ScienceDirect Materials Today: Proceedings 5 (2018) 12484–12489
www.materialstoday.com/proceedings
ICMMM - 2017
A Finite Element Analysis of Dissimilar Materials Diffusion Bonded Joints Deepak P1*, Latheesh V.M2 , Sumesh.A3 , Unnikrishnan D4 , Santhakumari. A5 1 2
, M.Tech Student, Department of Mechanical Engineering, Amrita School of Engineering, Coimbatore, Amrita Vishwa Vidypeetham, Amrita University, India-641112 3 4 , Assistant Professor, Department of Mechanical Engineering, Amrita School of Engineering, Coimbatore, Amrita Vishwa Vidypeetham, Amrita University, India-641112 5 Senior Deputy General Manager, WRI, BHEL, Tiruchirappalli, India-620014
Abstract Diffusion bonding is one of the solid state joining process, in which two clean metallic surfaces intended for joining were brought into contact at elevated temperatures under optimum pressure. In this work, an attempt is made to study the analysis and simulation of the two dissimilar materials Titanium alloy (Ti-6Al-4V) and Stainless Steel (SS304) which is having a wide application in the area of aerospace. Structural analysis was carried out to determine the equivalent stress, elongation and total deformation of the welded joint. Explicit Dynamics analysis using Ansys was used to predict the strength of Ti-6Al-4V/SS304 diffusion bonded joint. The result indicates that Equivalent stress is attained at 1.393GPa and total deformation is 0.00275m obtained at a time 0.000041seconds. The analysis shows that the fracture occurs in the region of titanium alloy and not in the region of HAZ. © 2017 Elsevier Ltd. All rights reserved. Selection and/or Peer-review under responsibility of International Conference on Materials Manufacturing and Modelling (ICMMM - 2017).
Keywords: Diffusion bonding, Dissimilar material joint analysis, Explicit Dynamics Analysis. 1. Introduction Welding is the most widely accepted joining technique in which joining was done due to the heat generated at the interface causes melting. The heat generation can be done with or without pressure and join can be done with or without using filler material. Diffusion bonding is a solid state joining process [1]. During solid state welding two clean metallic surfaces are brought into contact at optimum pressure which generates sufficient heat to diffuse the atoms between joining materials [2]. Diffusion bonding produces high quality joints without post weld machining
* Corresponding author Email address: [email protected]
2214-7853 © 2017 Elsevier Ltd. All rights reserved. Selection and/or Peer-review under responsibility of International Conference on Materials Manufacturing and Modelling (ICMMM - 2017).
Deepak P et al./ Materials Today: Proceedings 5 (2018) 12484–12489
12485
[3]. Heat affected zone related welding problems are eliminated in diffusion welding joint due to the lower joining temperature at joints [4]. Diffusion bonding can be done, with or without an interlayer as discussed by Church S.C and Elrefaey [5-6]. Low alloy steels and hard wearing steels with and without the use of interlayers (Ni, Cu, and V). Alloys, metals, ceramics and composites can be joined using diffusion bonding method with less macroscopic deformation [7]. Diffusion bonding provides novel joining operation for dissimilar and similar materials without any gross microscopic distortion and also with close dimensional tolerance. Joining of varieties of similar and dissimilar materials has already been carried out by diffusion bonding technique [8]. During the process of diffusion bonding, the surfaces need to be smooth and also to be free from contaminants. Once they came into intimate which are smooth intimate contact by apply sufficient pressure to make the diffusion bonded joint. Initially applied pressure causes yielding at the interface of the joining materials and thereby establishes a perfect contact between the surfaces to be bonded. Atomic diffusion as well as continuous creep deformation due to applied pressure taking place during bonding leads to the closure of interfacial voids followed by bonding of materials. The pressure applied will cause only deformation of asperities and not bulk deformation [9-11]. Titanium alloys (Ti-6Al-4V) having good mechanical properties, specific strength, corrosion resistance and ability to withstand high temperature make it a good candidate in aerospace, biomedical and nuclear applications such as Frames ,joints ,turbo fan engines compressor blades, fan discs, fan blades, bolts, seat rails, shaft, landing gear[12-14]. During direct diffusion bonding without interlayers between titanium and stainless steel alloys will result in the formation of intermetallic compounds (IMCs) such as TiFe, TiFe2, σ (with a composition of Fe–Cr–Ti– Ni), Fe2Ti4O and TiC reported in the literatures [15-19], which also embrittle the joints [20]. Very few finite element studies has been reported in diffusion bonding of dissimilar materials (Titanium alloy and Stainless Steel). Chemical composition of the Titanium alloy is shown in Table 1 and similarly that of Stainless Steel 304 is shown in Table 2. Table1: Chemical Composition of Titanium Alloy (Ti-6Al-4V) [20] Elements
Al
V
C
Fe
O2
N2
H2
Ti
Wt.%
6.3
4
0.006
0.17
0.166
0.006
0.002
89.35
Table 2: Chemical Composition of Stainless Steel 304(SS304) [20] Elements
C
Si
Mn
Cr
Ni
S
P
Fe
Wt.%
0.05
0.52
0.82
18.7
8.765
0.014
0.011
71.12
Finite Element Analysis (FEA) is a numerical technique for finding imprecise solutions to the boundary value problems for partial differential equations (PDE). It separates a sizeable problem into small and simple parts. FEA is implemented in engineering as a computational tool for performing engineering analysis. FEA is a practical application of finite element method it includes the use of mesh generation techniques for dividing a complex problem into small elements. Great mismatch of thermal expansion coefficients of metals take place, and also thermal stress appears in the vicinity of the bonded interfaces [21-22]. FEA software can be employ in all inclusive of industries, often used in automotive, biomechanical and aerospace industries. We focus our attention on thermal stresses across the joint; the thermal stresses may be influenced by the resulting microscopic changes in thermal expansion coefficient, modulus of elasticity and Poisson’s ratio. In this Ti-6Al-4V and SS304 diffusion bonding of dissimilar materials was also analyzed using Finite element analysis. 2. FEA Modelling Numerical modelling of a tensile testing specimen of a diffusion bonded Titanium alloy-Stainless Steel 304 was done using Ansys® Work Bench14.5 which is shown as in figure 1.
12486
Deepak P et al./ Materials Today: Proceedings 5 (2018) 12484–12489
Figure 1 Model The dimension of the model is taken from ASTM standard code IS1608-1972 and IS1432-1966. The diffusion bond was created by using direct mesh bonding approach between the materials. Table 3 shows the material data which is taken from ASTM Standards and is used in the Finite element analysis. Explicit dynamics were used in order to facilitate all small deformations to be recorded. Table 3: Parameters of Ti-6Al-4V and SS304 Parameters
Poisson Ratio
Young’s modulus
Thermal Conductivity
Titanium Alloy
0.31
110GPa
7.1 W/m.K
Stainless Steel 304
0.265
190GPa
16.2 W/m.K
Structural meshing is done on the model so as to improve the quality of the result. The area near to the bonding is given very fine mesh with an Element size of 0.001 m is shown in figure 2.
Figure 2 Meshing 2.1 Boundary conditions and load: The broad end of the Stainless-Steel side of the specimen was arrested for all 6 degrees of freedom. Load of 10 GPa was applied at the broader volume to simulate a typical tension tests as is shown in figure 3.
Deepak P et al./ Materials Today: Proceedings 5 (2018) 12484–12489
12487
Figure 3 Force applied
Inbuilt parameters from workbench were taken for the analysis settings and the process is program controlled. Further process is done by step control values which were shown in Table 4. The measurement values of the materials are described using the solver units which consist of millimeters, milligrams, milliseconds. Maximum number of cycles chosen for the study is 5000 in order to ensure that cyclic loading till fracture occurs. Since in Explicit Dynamics short cycles will consume only milliseconds of time. The end time was chosen based on the time required for one cycle to complete. Maximum velocity was an inbuilt parameter for the analysis. Table 4: Explicit Dynamics parameters Maximum number of cycles
5000
End time
0.0007 sec
Solver units
mm, mg, ms
Maximum velocity
1e10 m/s
X- Component
0N
Y- Component
+10000000 (ramped)
Z- Component
0N
3. Result and Discussions Mesh refinement and optimization studies has been carried out by finite element analysis. Each analysis was run 3 to 4 times in order to ensure that no errors or mismatches to be reported. The following results were discussed in the subsequent headings. 3.1 Equivalent Stress The result show that Titanium alloy breaks away from the diffusion bond within the parent material. Due to cyclic loading, cyclic plasticity occurs in a non-linear stress-strain of a material. In this materials Elastic and plastic plays a pivotal role in failure and design. Titanium have lesser shear modulus less than SS 304 i.e. values of Ti-6Al-4V (44GPa) and SS304 (86GPa) obtained from ASTM, so when stress-strain occurs on the specimen plastic deformation normally occur on the weaker section, in the region of Titanium alloy which was shown in the figure 4.
12488
Deepak P et al./ Materials Today: Proceedings 5 (2018) 12484–12489
Figure 4 Equivalent Stress- Fracture 3.2 Total Deformation When certain force of 10 GPa is applied, an elastic and plastic deformation occurs on Diffusion Bonded joints. When two dissimilar materials are joined and subjected to tensile loading, the elongation will not be uniform. It depends on the fatigue or endurance limit of the materials which is used in the joint. Titanium alloy having endurance limit of 529 MPa and that of SS 304 was 240 MPa. For Lesser endurance limit, elongation will be more and is less prone to material breakage in that section. At a time period of 0.000035 seconds. The maximum elongation was found to be 0.008m for the welded specimen. The details were shown in the below figure 5.
Figure 5 Total Deformation 4. Conclusions In the present study, Diffusion bonding of Titanium alloy and AISI Stainless Steel 304 were investigated by Finite Element Analysis using ANSYS Workbench. Explicit Dynamic analysis was used to study the Equivalent Stress and Total Deformation in the joint. Simulation was done under vacuum atmosphere created in the software.
Deepak P et al./ Materials Today: Proceedings 5 (2018) 12484–12489
12489
Since in the actual welding the experiments will be carried out under vacuum condition. The applied pressure of 10 GPa was used to determine the joint strength and elongation. From the analysis of Equivalent Stress (Von Mises) fracture occurs in the area of Titanium alloy since the shear modulus of Titanium alloy is lesser than SS304. Due to higher bonding strength, the necking happens in the area of Titanium alloy which is visible from the analysis. The maximum deformation obtained in the analysis was 0.008m and the maximum stress which the joint can withstand is 127MPa. The experimental validation is in progress. The analysis validates the theoretical fracture conditions References [1] A.Sumesh, K. Rameshkumar., K.Mohandas, R.Shyam Babu “Use of Machine Learning Algorithms for Weld Quality Monitoring using Acoustic Signature” Procedia Computer Science Volume 50, 2015, Pages 316-322 [2] Orhan, N.; Khan, T.I.; and Eroglu, M. (2001). Diffusion bonding of a microduplex stainless steel to Ti–6Al–4V. Scripta Materialia, 45, 441446. [3] Kliauga, A.M.; Travessa, D.; and Ferrante M. (2001). Al2O3/Ti interlayer / AISI 304 diffusion bonded joint. Microstructural characterization of the two interfaces. Material Characterization, 46, 65-74. [4] R. Padmanaban , V. Ratna Kishore , and V. Balusamy (2014). Numerical Simulation of Temperature Distribution and Material Flow during Friction Stir Welding of Dissimilar Aluminum Alloys. [5] Church, S.C., Wild, R.W., 1998. Diffusion bonding of steel to Ti-6Al-4V to produce hard wearing surface layers. J. Vac. Sci. Technol. A 16 (3), 1885–1889. [6] Elrefaey, A., Tillmann, W., 2009. Solid state diffusion bonding of titanium to steel using a copper base alloy as interlayer. J. Mater. Process. Technol. 209,2746–2752 [7] M. Kocak G. Cam. Studies on creep/stress rupture behavior of superalloy 718 weldments used in gas turbine applications. Int. Mater. Rev., 43:1–44, 1998. [8] W.A.Owczarski W.H. King. Diffusion welding of commercially pure titanium. Weld J., 46:289, 1967. [9] Kundu S, Chatterjee S. Interface microstructure and strength properties of diffusion bonded joints of titanium–Al interlayer–18Cr–8Ni stainless steel. Mater Sci Eng A 2010; 527:2714–9. [10] D.L.Olson S. Kundu, B. Mishra S. Chatterjee (2013) Interfacial reactions and strength properties of diffusion bonded joints of Ti64 alloy and 17-4PH stainless steel using nickel alloy interlayer. Materials & Design, Volume 51. [11] Li, Y.; Liu, P.; Wang, J.; and Ma, H. (2008). XRD and SEM analysis near the Diffusion bonding interface of Mg/Al dissimilar materials. Vacuum. [12] P. Krishnakumar, , , K. Rameshkumar, K.I. Ramachandran, Tool Wear Condition Prediction Using Vibration Signals in High Speed Machining (HSM) of Titanium (Ti-6Al-4 V) Alloy by Procedia Computer Science Volume 50, 2015, Pages 270–275. [13] GAO Yefei, TSUMURA Takuya, NAKATA Kazuhiro (2012). Dissimilar welding of Titanium alloys and Steels. [14] Kundu S, Ghosh M, Laik A, Bhanumurthy K, Kale GB, Chatterjee S. Diffusion bonding of commercially pure titanium to 304 stainless steel using copper interlayer. Mater Sci Eng A 2005; 407:154–60. [15] Ghosh M, Chatterjee S. Characterization of transition joint of commercially pure titanium to 304 stainless steel. MaterCharact 2002; 48:393– 9. [16] Ghosh M, Chatterjee S. Diffusion bonded transition joints of titanium to stainless steel with improved properties. Mater Sci Eng A 2003; 358:152–8. [17] Alemán B, Gutiérrez I, Urcola JJ. Interface microstructures in diffusion bonding of titanium alloys to stainless and low alloy steels. Mater Sci Technol 1993; 9:633–41. [18] Kundu S, Sam S, Chatterjee S. Interface microstructure and strength properties of Ti–6Al–4V and microduplex stainless steel diffusion bonded joints. Mater Des 2011; 32:2997–3003. [19] Ikuhiro INAGAKI, Tsutomu TAKECHI, Yoshihisa SHIRAI, Nozomu ARIYASU (2014) Applications and Features of Titanium for Aerospace Industry. [20] Balasubramanian, M., G. Ramesh, and V. Balasubramanian. "Diffusion Bonding Of Titanium Alloy Ti-6al-4v and AISI 304 Stainless Steel– An Experimental Investigation." Journal of Engineering Science and Technology 10.10 (2015): 1342-1349. [21] D. Munz and y. y. yang: J. Appl. Mech., 1992, 59, (2), 857– 862. [22] S.-B. lee and J.-H. Kim: J. Mater. Process. Technol., 1997, 67, (1), 167 – 172.
ScienceDirect Materials Today: Proceedings 5 (2018) 12484–12489
www.materialstoday.com/proceedings
ICMMM - 2017
A Finite Element Analysis of Dissimilar Materials Diffusion Bonded Joints Deepak P1*, Latheesh V.M2 , Sumesh.A3 , Unnikrishnan D4 , Santhakumari. A5 1 2
, M.Tech Student, Department of Mechanical Engineering, Amrita School of Engineering, Coimbatore, Amrita Vishwa Vidypeetham, Amrita University, India-641112 3 4 , Assistant Professor, Department of Mechanical Engineering, Amrita School of Engineering, Coimbatore, Amrita Vishwa Vidypeetham, Amrita University, India-641112 5 Senior Deputy General Manager, WRI, BHEL, Tiruchirappalli, India-620014
Abstract Diffusion bonding is one of the solid state joining process, in which two clean metallic surfaces intended for joining were brought into contact at elevated temperatures under optimum pressure. In this work, an attempt is made to study the analysis and simulation of the two dissimilar materials Titanium alloy (Ti-6Al-4V) and Stainless Steel (SS304) which is having a wide application in the area of aerospace. Structural analysis was carried out to determine the equivalent stress, elongation and total deformation of the welded joint. Explicit Dynamics analysis using Ansys was used to predict the strength of Ti-6Al-4V/SS304 diffusion bonded joint. The result indicates that Equivalent stress is attained at 1.393GPa and total deformation is 0.00275m obtained at a time 0.000041seconds. The analysis shows that the fracture occurs in the region of titanium alloy and not in the region of HAZ. © 2017 Elsevier Ltd. All rights reserved. Selection and/or Peer-review under responsibility of International Conference on Materials Manufacturing and Modelling (ICMMM - 2017).
Keywords: Diffusion bonding, Dissimilar material joint analysis, Explicit Dynamics Analysis. 1. Introduction Welding is the most widely accepted joining technique in which joining was done due to the heat generated at the interface causes melting. The heat generation can be done with or without pressure and join can be done with or without using filler material. Diffusion bonding is a solid state joining process [1]. During solid state welding two clean metallic surfaces are brought into contact at optimum pressure which generates sufficient heat to diffuse the atoms between joining materials [2]. Diffusion bonding produces high quality joints without post weld machining
* Corresponding author Email address: [email protected]
2214-7853 © 2017 Elsevier Ltd. All rights reserved. Selection and/or Peer-review under responsibility of International Conference on Materials Manufacturing and Modelling (ICMMM - 2017).
Deepak P et al./ Materials Today: Proceedings 5 (2018) 12484–12489
12485
[3]. Heat affected zone related welding problems are eliminated in diffusion welding joint due to the lower joining temperature at joints [4]. Diffusion bonding can be done, with or without an interlayer as discussed by Church S.C and Elrefaey [5-6]. Low alloy steels and hard wearing steels with and without the use of interlayers (Ni, Cu, and V). Alloys, metals, ceramics and composites can be joined using diffusion bonding method with less macroscopic deformation [7]. Diffusion bonding provides novel joining operation for dissimilar and similar materials without any gross microscopic distortion and also with close dimensional tolerance. Joining of varieties of similar and dissimilar materials has already been carried out by diffusion bonding technique [8]. During the process of diffusion bonding, the surfaces need to be smooth and also to be free from contaminants. Once they came into intimate which are smooth intimate contact by apply sufficient pressure to make the diffusion bonded joint. Initially applied pressure causes yielding at the interface of the joining materials and thereby establishes a perfect contact between the surfaces to be bonded. Atomic diffusion as well as continuous creep deformation due to applied pressure taking place during bonding leads to the closure of interfacial voids followed by bonding of materials. The pressure applied will cause only deformation of asperities and not bulk deformation [9-11]. Titanium alloys (Ti-6Al-4V) having good mechanical properties, specific strength, corrosion resistance and ability to withstand high temperature make it a good candidate in aerospace, biomedical and nuclear applications such as Frames ,joints ,turbo fan engines compressor blades, fan discs, fan blades, bolts, seat rails, shaft, landing gear[12-14]. During direct diffusion bonding without interlayers between titanium and stainless steel alloys will result in the formation of intermetallic compounds (IMCs) such as TiFe, TiFe2, σ (with a composition of Fe–Cr–Ti– Ni), Fe2Ti4O and TiC reported in the literatures [15-19], which also embrittle the joints [20]. Very few finite element studies has been reported in diffusion bonding of dissimilar materials (Titanium alloy and Stainless Steel). Chemical composition of the Titanium alloy is shown in Table 1 and similarly that of Stainless Steel 304 is shown in Table 2. Table1: Chemical Composition of Titanium Alloy (Ti-6Al-4V) [20] Elements
Al
V
C
Fe
O2
N2
H2
Ti
Wt.%
6.3
4
0.006
0.17
0.166
0.006
0.002
89.35
Table 2: Chemical Composition of Stainless Steel 304(SS304) [20] Elements
C
Si
Mn
Cr
Ni
S
P
Fe
Wt.%
0.05
0.52
0.82
18.7
8.765
0.014
0.011
71.12
Finite Element Analysis (FEA) is a numerical technique for finding imprecise solutions to the boundary value problems for partial differential equations (PDE). It separates a sizeable problem into small and simple parts. FEA is implemented in engineering as a computational tool for performing engineering analysis. FEA is a practical application of finite element method it includes the use of mesh generation techniques for dividing a complex problem into small elements. Great mismatch of thermal expansion coefficients of metals take place, and also thermal stress appears in the vicinity of the bonded interfaces [21-22]. FEA software can be employ in all inclusive of industries, often used in automotive, biomechanical and aerospace industries. We focus our attention on thermal stresses across the joint; the thermal stresses may be influenced by the resulting microscopic changes in thermal expansion coefficient, modulus of elasticity and Poisson’s ratio. In this Ti-6Al-4V and SS304 diffusion bonding of dissimilar materials was also analyzed using Finite element analysis. 2. FEA Modelling Numerical modelling of a tensile testing specimen of a diffusion bonded Titanium alloy-Stainless Steel 304 was done using Ansys® Work Bench14.5 which is shown as in figure 1.
12486
Deepak P et al./ Materials Today: Proceedings 5 (2018) 12484–12489
Figure 1 Model The dimension of the model is taken from ASTM standard code IS1608-1972 and IS1432-1966. The diffusion bond was created by using direct mesh bonding approach between the materials. Table 3 shows the material data which is taken from ASTM Standards and is used in the Finite element analysis. Explicit dynamics were used in order to facilitate all small deformations to be recorded. Table 3: Parameters of Ti-6Al-4V and SS304 Parameters
Poisson Ratio
Young’s modulus
Thermal Conductivity
Titanium Alloy
0.31
110GPa
7.1 W/m.K
Stainless Steel 304
0.265
190GPa
16.2 W/m.K
Structural meshing is done on the model so as to improve the quality of the result. The area near to the bonding is given very fine mesh with an Element size of 0.001 m is shown in figure 2.
Figure 2 Meshing 2.1 Boundary conditions and load: The broad end of the Stainless-Steel side of the specimen was arrested for all 6 degrees of freedom. Load of 10 GPa was applied at the broader volume to simulate a typical tension tests as is shown in figure 3.
Deepak P et al./ Materials Today: Proceedings 5 (2018) 12484–12489
12487
Figure 3 Force applied
Inbuilt parameters from workbench were taken for the analysis settings and the process is program controlled. Further process is done by step control values which were shown in Table 4. The measurement values of the materials are described using the solver units which consist of millimeters, milligrams, milliseconds. Maximum number of cycles chosen for the study is 5000 in order to ensure that cyclic loading till fracture occurs. Since in Explicit Dynamics short cycles will consume only milliseconds of time. The end time was chosen based on the time required for one cycle to complete. Maximum velocity was an inbuilt parameter for the analysis. Table 4: Explicit Dynamics parameters Maximum number of cycles
5000
End time
0.0007 sec
Solver units
mm, mg, ms
Maximum velocity
1e10 m/s
X- Component
0N
Y- Component
+10000000 (ramped)
Z- Component
0N
3. Result and Discussions Mesh refinement and optimization studies has been carried out by finite element analysis. Each analysis was run 3 to 4 times in order to ensure that no errors or mismatches to be reported. The following results were discussed in the subsequent headings. 3.1 Equivalent Stress The result show that Titanium alloy breaks away from the diffusion bond within the parent material. Due to cyclic loading, cyclic plasticity occurs in a non-linear stress-strain of a material. In this materials Elastic and plastic plays a pivotal role in failure and design. Titanium have lesser shear modulus less than SS 304 i.e. values of Ti-6Al-4V (44GPa) and SS304 (86GPa) obtained from ASTM, so when stress-strain occurs on the specimen plastic deformation normally occur on the weaker section, in the region of Titanium alloy which was shown in the figure 4.
12488
Deepak P et al./ Materials Today: Proceedings 5 (2018) 12484–12489
Figure 4 Equivalent Stress- Fracture 3.2 Total Deformation When certain force of 10 GPa is applied, an elastic and plastic deformation occurs on Diffusion Bonded joints. When two dissimilar materials are joined and subjected to tensile loading, the elongation will not be uniform. It depends on the fatigue or endurance limit of the materials which is used in the joint. Titanium alloy having endurance limit of 529 MPa and that of SS 304 was 240 MPa. For Lesser endurance limit, elongation will be more and is less prone to material breakage in that section. At a time period of 0.000035 seconds. The maximum elongation was found to be 0.008m for the welded specimen. The details were shown in the below figure 5.
Figure 5 Total Deformation 4. Conclusions In the present study, Diffusion bonding of Titanium alloy and AISI Stainless Steel 304 were investigated by Finite Element Analysis using ANSYS Workbench. Explicit Dynamic analysis was used to study the Equivalent Stress and Total Deformation in the joint. Simulation was done under vacuum atmosphere created in the software.
Deepak P et al./ Materials Today: Proceedings 5 (2018) 12484–12489
12489
Since in the actual welding the experiments will be carried out under vacuum condition. The applied pressure of 10 GPa was used to determine the joint strength and elongation. From the analysis of Equivalent Stress (Von Mises) fracture occurs in the area of Titanium alloy since the shear modulus of Titanium alloy is lesser than SS304. Due to higher bonding strength, the necking happens in the area of Titanium alloy which is visible from the analysis. The maximum deformation obtained in the analysis was 0.008m and the maximum stress which the joint can withstand is 127MPa. The experimental validation is in progress. The analysis validates the theoretical fracture conditions References [1] A.Sumesh, K. Rameshkumar., K.Mohandas, R.Shyam Babu “Use of Machine Learning Algorithms for Weld Quality Monitoring using Acoustic Signature” Procedia Computer Science Volume 50, 2015, Pages 316-322 [2] Orhan, N.; Khan, T.I.; and Eroglu, M. (2001). Diffusion bonding of a microduplex stainless steel to Ti–6Al–4V. Scripta Materialia, 45, 441446. [3] Kliauga, A.M.; Travessa, D.; and Ferrante M. (2001). Al2O3/Ti interlayer / AISI 304 diffusion bonded joint. Microstructural characterization of the two interfaces. Material Characterization, 46, 65-74. [4] R. Padmanaban , V. Ratna Kishore , and V. Balusamy (2014). Numerical Simulation of Temperature Distribution and Material Flow during Friction Stir Welding of Dissimilar Aluminum Alloys. [5] Church, S.C., Wild, R.W., 1998. Diffusion bonding of steel to Ti-6Al-4V to produce hard wearing surface layers. J. Vac. Sci. Technol. A 16 (3), 1885–1889. [6] Elrefaey, A., Tillmann, W., 2009. Solid state diffusion bonding of titanium to steel using a copper base alloy as interlayer. J. Mater. Process. Technol. 209,2746–2752 [7] M. Kocak G. Cam. Studies on creep/stress rupture behavior of superalloy 718 weldments used in gas turbine applications. Int. Mater. Rev., 43:1–44, 1998. [8] W.A.Owczarski W.H. King. Diffusion welding of commercially pure titanium. Weld J., 46:289, 1967. [9] Kundu S, Chatterjee S. Interface microstructure and strength properties of diffusion bonded joints of titanium–Al interlayer–18Cr–8Ni stainless steel. Mater Sci Eng A 2010; 527:2714–9. [10] D.L.Olson S. Kundu, B. Mishra S. Chatterjee (2013) Interfacial reactions and strength properties of diffusion bonded joints of Ti64 alloy and 17-4PH stainless steel using nickel alloy interlayer. Materials & Design, Volume 51. [11] Li, Y.; Liu, P.; Wang, J.; and Ma, H. (2008). XRD and SEM analysis near the Diffusion bonding interface of Mg/Al dissimilar materials. Vacuum. [12] P. Krishnakumar, , , K. Rameshkumar, K.I. Ramachandran, Tool Wear Condition Prediction Using Vibration Signals in High Speed Machining (HSM) of Titanium (Ti-6Al-4 V) Alloy by Procedia Computer Science Volume 50, 2015, Pages 270–275. [13] GAO Yefei, TSUMURA Takuya, NAKATA Kazuhiro (2012). Dissimilar welding of Titanium alloys and Steels. [14] Kundu S, Ghosh M, Laik A, Bhanumurthy K, Kale GB, Chatterjee S. Diffusion bonding of commercially pure titanium to 304 stainless steel using copper interlayer. Mater Sci Eng A 2005; 407:154–60. [15] Ghosh M, Chatterjee S. Characterization of transition joint of commercially pure titanium to 304 stainless steel. MaterCharact 2002; 48:393– 9. [16] Ghosh M, Chatterjee S. Diffusion bonded transition joints of titanium to stainless steel with improved properties. Mater Sci Eng A 2003; 358:152–8. [17] Alemán B, Gutiérrez I, Urcola JJ. Interface microstructures in diffusion bonding of titanium alloys to stainless and low alloy steels. Mater Sci Technol 1993; 9:633–41. [18] Kundu S, Sam S, Chatterjee S. Interface microstructure and strength properties of Ti–6Al–4V and microduplex stainless steel diffusion bonded joints. Mater Des 2011; 32:2997–3003. [19] Ikuhiro INAGAKI, Tsutomu TAKECHI, Yoshihisa SHIRAI, Nozomu ARIYASU (2014) Applications and Features of Titanium for Aerospace Industry. [20] Balasubramanian, M., G. Ramesh, and V. Balasubramanian. "Diffusion Bonding Of Titanium Alloy Ti-6al-4v and AISI 304 Stainless Steel– An Experimental Investigation." Journal of Engineering Science and Technology 10.10 (2015): 1342-1349. [21] D. Munz and y. y. yang: J. Appl. Mech., 1992, 59, (2), 857– 862. [22] S.-B. lee and J.-H. Kim: J. Mater. Process. Technol., 1997, 67, (1), 167 – 172.