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Tube Expansion and Hybrid Friction Diffusion Bonding of Cu-Ni and ASTM A516 G70 Tube-to-Tubesheet Joints

[+] Author Affiliations
Abdulellah Hbbani, Fadi Al-Badour, Abdelaziz Bazoune

King Fahd University of Petroleum and Minerals, Dhahran, Saudi Arabia

Paper No. PVP2017-66064, pp. V06BT06A028; 6 pages
  • ASME 2017 Pressure Vessels and Piping Conference
  • Volume 6B: Materials and Fabrication
  • Waikoloa, Hawaii, USA, July 16–20, 2017
  • Conference Sponsors: Pressure Vessels and Piping Division
  • ISBN: 978-0-7918-5800-4
  • Copyright © 2017 by ASME


Hybrid Friction Diffusion Bonding (HFDB) is a solid-state welding process. The development of HFDB process in achieving quality joints in tube-to-tubesheet heat exchangers is constrained on tube thickness of 1 mm and similarity of tube and tubesheet materials. In nuclear and petrochemical industries, there is significant demand on steel, copper-nickel, and dissimilar shell and tube (tube-tubesheet) heat exchangers. The present study evaluates the feasibility of HFDB on copper-nickel tubes into steel tubesheets with a tube thickness of 1.26 mm. To avoid relative movement of tubes with respect to the tubesheet, tubes are expanded prior to HFDB using commercial roller expander. The effect of tool rotational speed on joint strength and developed macrostructure was investigated employing mechanical pull-out tests to validate safe operation of the joint, and optical microscopy, respectively. Moreover, a comparison between expanded and welded-and-expanded tube-to-tubesheet joints is carried out.

Copyright © 2017 by ASME



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