Abstract
Tungsten/molybdenum alloys are widely utilized in the nuclear industry, aerospace and various other fields due to their high melting points and strength characteristics. However, poor sinterability and processability make it difficult to manufacture large-size or complex-shaped parts. Hence, an in-depth study on the welding technology of tungsten/molybdenum alloys is urgent. An introduction of tungsten/molybdenum alloy welding defects and joining process was provided, along with recent advancements in brazing, spark plasma sintering diffusion bonding, electron beam welding and laser beam welding. The latest progress in alloy doping treatment applied to tungsten/molybdenum alloy dissimilar welding was also discussed, and existing welding problems were pointed out. The development prospects of weldability of tungsten/molybdenum alloy by various joining technologies were forecasted, thereby furnishing a theoretical and practical found.
Molybdenum alloys possess unique properties, such as high melting point, high strength, high corrosion resistance, good thermal and electrical conductivity, which have been widely used in nuclear energy, shipbuilding, aerospace and petrochemicals (e.g., rocket nozzle throats and nuclear fuel rod sets
Tungsten alloy and molybdenum alloy are characterized by high brittleness, low ductile-brittle transition temperature and poor weld abilit
Brazing is a method in which low-melting-point filler metal is melted and used to fill the gaps between solid workpieces. Part of defects during weld processes can be avoided by choosing appropriate brazing material. Additionally, the formation of brittle phase can be suppressed by adjusting the brazing material and soldering temperatur
This study started from the welding defects of tungsten alloy and molybdenum alloy, summarized the research status of brazing, SPS diffusion welding, EBW, and LBW in the field of tungsten alloy and molybdenum alloy welding, and looked forward to the development trend. The definitive purpose is to provide a theoretical basis and technical support for the research and application of tungsten/molybdenum alloy welded joints in related fields.
Tungsten/molybdenum alloy joints suffer from two major defects: brittleness and porosity. There are two main reasons for brittleness. Firstly, tungsten and molybdenum alloys are inherently brittle; secondly, the heat input of different welding methods affects the grain size, leading to varying degrees of brittleness in the joint. Micropores generated during powder metallurgy preparation absorbed impurities and inadequate weld preparation can introduce gas into the molten pool. Incomplete gas drainage from the joint during solidification leads to porosity.
Due to high ductile-to-brittle transition temperature of tung-sten alloys and molybdenum alloys, they exhibit brittleness at room temperature. The primary intrinsic reason is the half-filled electron distribution characteristics of the outermost and penultimate atomic layer
Manufactured by powder metallurgy, tungsten alloy and molybdenum alloy contain interstitial impurities (C, N, O, P, etc). During the welding process, some impurities entering the molten pool are diffused and enriched sufficiently along the grain boundaries, which will weaken the interfacial bonding. Oxygen has the most significant effect in this regard. At a microscopic level, the enrichment of trace interstitial impurities along the grain boundaries prompts the generation of the second phase (MoO2 and WO2). As depicted in

Fig.1 TEM images of fusion zone of laser welded Mo alloy joints with different heat inputs: (a) 250 J/cm and (b) 3600 J/c
Weld embrittlement is mainly caused by the difference in strength between the weld metal and base metal (BM). The variance in heat input among different welding methods significantly affects the microstructure of BM and HAZ, thereby resulting in different mechanical properties. The main causes of brittleness at the interface are coarse grain and the formation of brittle intermetallics and oxides. Brazing has relatively low heat input, and the joints experience less thermal stress during the welding process, resulting in relatively fewer problems of coarse grain. However, localized embrittlement still occurs if compatibility between the brazing material and BM is poor or if a large number of impurities are presente

Fig.2 Microstructures of EBWed TZM alloy joints: (a) weld cross section, (b) WZ, (c) FZ, (d) HAZ, and (e) BM (regions b–e in Fig.2a correspond to Fig.2b–2e, respectively
Tungsten/molybdenum alloys usually suffer from porosity defects during welding processes, which seriously deteriorates the weld quality of the joints. As shown in
At present, tungsten/molybdenum alloy welding methods mainly include brazing, SPS diffusion welding, EBW, and LBW. The advantages and disadvantages of different welding methods, as well as their improvements and developments, are shown in

Fig.3 Characteristics of different welding methods for tungsten/molybdenum alloy
Welding method | Welded joint | Shear strength/MPa | Tensile strength/MPa | Ref. |
---|---|---|---|---|
Brazing |
TZM/Ni-44Ti/TZM TZM/Ni-13.7Ti/TZM |
167 193 | - |
[ |
TZM/Ti-28Ni/ZrCp-W |
120.5 77.5 (800 °C) | - |
[ | |
TZM/Ti-61Ni/ZrCp-W |
124.8 82.3 (800 °C) | - |
[ | |
TZM/Ti-35Ni/ZrCp-W |
123.8 110.2 (800 °C) | - |
[ | |
TZM/Ti-50Ni/ZrCp-W | 146 | - |
[ | |
SPS diffusion bonding | TZM/WRe | 498±32.5 | 475±19.8 |
[ |
WRe/TZM | 279.92 | - |
[ | |
ODS-W/TZM | - | 485 |
[ | |
TZM/WRe | - | 497±50 |
[ | |
EBW |
TZM/TZM (350 mm/min) TZM/TZM (370 mm/min) TZM/TZM (390 mm/min) | - |
403 364 256 |
[ |
Mo/Kovar (no offset) Mo/Kovar (offset 0.6 mm) | - |
190 262 |
[ | |
TZM/30CrMnSiA (beam current=24 mA) | - | 191.3 |
[ | |
TZM/TZM TZM/Zr/TZM | - |
362 452 |
[ | |
TZM/TZM TZM/Re/TZM | - |
362 524 |
[ | |
TZM/30CrMnSiA TZM/V/30CrMnSiA | - |
165.2 312.7 |
[ | |
LBW |
NS-Mo/NS-Mo (3600 J/cm) NS-Mo/NS-Mo (250 J/cm) | - |
250 570 |
[ |
Mo/Ti (offset 0.5 mm) | - | 350 |
[ | |
Mo/301SS (offset 0.3 mm) | - | 290 |
[ | |
La2O3-Mo/La2O3-Mo | 617 |
[ | ||
Mo-30W/Mo-30W Mo-30W/Ti/Mo-30W | - |
108.56 409.57 |
[ | |
Zr/Mo Zr/Ti/Mo | - |
76 321 |
[ | |
NS-Mo/NS-Mo NS-Mo/Zr/NS-Mo | - |
234 441 |
[ | |
La2O3-Mo/3Ti +1Zr/ La2O3-Mo | - | 430 |
[ | |
Mo/304L Mo/Ni/304L | - |
110 280 |
[ | |
Mo/Ni (0.1 mm)/301SS | - | 351 |
[ |
Brazing is one of the most commonly used methods for joining tungsten/molybdenum alloy dissimilar materials as it has the advantages of low operating temperature, small thermal effects, flat and smooth joints, and small residual stress deformation in the B
Lu et a
The fracture locations of the above Ti-Ni brazed joints were all located on the TZM side, as shown in

Fig.4 Cross-sectional BSE images of TZM/ZrCp-W joints (a, c, e) and SEM images of corresponding fracture surfaces (b, d, f) at different brazing temperatures: (a–b) 1000 °C, (c–d) 1040 °C, and (e–f) 1080 °

Fig.5 Melting of Ti-35Ni brazing material (a); diffusion of liquid TiNi alloy (b); formation of Ti-Mo solid solution and TiC (c); generation of TiNi (d); generation of Ti2Ni (e
In summary, future research directions include identifying optimal Ti-Ni ratio (Zr, Cr, Cu, etc), designing composite brazing structures, developing multilayer brazing materials, incorporating novel elements into brazing alloys, and explor-ing the implementation of diffusion barrier layers. There is a lack of effective theoretical models for the wetting and diffusion of brazing material, which requires more in-depth theoretical studies on brazing formation, as well as simulation of the forming process with the help of computer
SPS is a new method for diffusion joining of tungsten and molybdenum alloys, utilizing strong pulsed direct current to generate Joule heat and to rapidly consolidate the powde

Fig.6 Schematic diagrams of traditional (a) and improved (b) gra-phite die-punch assembly during SPS-assisted diffusion weldin
Liu et a

Fig.7 SEM images and EDS point-scan results of ODS-W/TZM alloy joints at different temperatures: (a) 1300 °C, (b) 1400 °C, (c) 1500 °C, and (d) 1600 °
WRe/TZM alloy welded joints are often used as CT scanner X-ray targets, where the tungsten alloy serves as the anode target surface material, bombarded by an electron beam to produce X-rays, and TZM alloy serves as the dielectric disk between the target surface and heat dissipating portio
Yang et a
Han et a
EBW of tungsten/molybdenum alloys, as a high-end welding technique, has the advantages of high energy density, fast welding speed, and small HA
The main welding parameters that affect the quality of tungsten/molybdenum alloy EBW joints include welding speed, beam offset position and beam current size. Different welding parameters can affect the welding efficiency and the distribution of precipitates, alter the morphology of the reaction layer, and lead to different mechanical propertie
Wang et a
Controlling the energy distribution by adjusting the electron beam current and the electron beam offset distance can opti-mize the mechanical properties of the joints. However, the im-provement is not significant, primarily because the embrittle-ment of the joints is not fundamentally resolved. The reliabi-lity of the joints can be enhanced by employing lowmelting-point filler materials. The addition of a suitable intermediate layer can prevent the formation of MoO2, furthering im-proving the grain structure, increasing the strength and toughness of the welded joints, and altering the fracture mode. The intermediate layer used to regulate the EBWed joints of TZM alloys is typically based on Zr, Re and V.
Wang et a

Fig.8 TEM micrographs of welded joints: (a) without adding zirconium; (b) purification of GBs region in joints after addition of zirconium; (c) ZrO2 particles distributed within the grain
Yu et a

Fig.9 Charge density at Mo (111)/Fe2Mo (100) interface (a) and Mo (111)/V(Fe)ss (111) interface (b
LBW technique for tungsten/molybdenum alloys is highly regarded for high energy density, precise control of heating position and heat input, narrow fusion zone and low residual stres
Similar to EBW, adjusting LBW parameters, including heat input, beam offset and interface gap, can regulate the microstructure of the tungsten/molybdenum alloy laser welded interface. This control enables grain refinement, reduces porosity, suppresses segregation and defect formation, and ultimately improves the mechanical properties and quality of the joints.
Xie et a

Fig.10 CT test (a–b) and statistical results (c–d) of porosity distribution of laser welded NS-Mo alloy joints at different heat inputs: (a, c) 250 J/cm and (b, d) 3600 J/c
Ning et a
The addition of Ti, Zr and Ni interlayers plays an important role in modulating the tungsten/molybdenum alloy weld interface in LBW. This includes inhibiting phase transfor-mations, reducing brittle phase formation, counteracting the weakening of joint strength by oxygen, modulating grain boundary structure, enhancing tensile strength, and influen-cing fracture mode.
Cheng et a
Zhang et a
Zhang et a

Fig.11 EPMA results for molybdenum/SUS304L laser welded Ni-free (a‒b) and Ni-bearing (c‒d) joint
Doping and alloying design not only improves the high-temperature strength, low-temperature plasticity and oxidation resistance of molybdenum and tungsten, but also plays an important role in enhancing the quality of tungsten/molybdenum alloy welded joint
In the previous sections, SPS diffusion welding of ODS-W/TZM, doped with Y2O3 particles, can promote the diffusion of elements at the joint, thereby enhancing the mechanical properties of the joint. La2O3-Mo alloy laser lap welding under different welding parameters yielded good mechanical properties of the joint
Wang et a

Fig.12 Fracture surface images of pure W (a, c) and W-Y alloys (b, d) after SPS sintering and disruptio
Compared with oxide diffusion strengthening, doping TiC, ZrC or other carbide particles can effectively inhibit grain growth and grain boundary migration of the molybdenum matrix, resulting in a uniform grain structure and excellent high-temperature strength and toughnes
Zhang et a
Tungsten/molybdenum alloy welding is considered benefi-cial for structural lightweighting and cost reduction, offering broad application prospects. However, it still faces unresolved issues, such as joint brittleness, porosity, unknown mechanism and weak strength in the HAZ. Introducing new welding methods or combinations of welding techniques, as well as the utilization of modern analytical techniques, such as computer simulation, artificial intelligence and machine learning, is essential for conducting more in-depth and comprehensive studies on the effects of welding process on microstructure and mechanical properties of welded joints. This approach aims to achieve highly efficient and high-quality welding production.
During the brazing of TZM and ZrCp-W alloys, brittle compounds tend to form at the welded joint, and intergranular penetration in the molybdenum alloy matrix may lead to cracks, thereby reducing the toughness and strength of the welded joint. Current research primarily focuses on the Ti-Ni filler metal ratio or evaluating the interfacial microstructure and bonding performance of the brazed joints through a series of conventional temperature tests and characterization me-thods. However, microstructural control remains suboptimal, and the impact of intergranular penetration on the joint has not been resolved. The region near the brazing seam in the TZM alloy matrix is identified as the weakest part of the joint.
The main challenge in the SPS diffusion bonding of tungsten alloy and molybdenum alloy is the precision control of temperature and the accuracy of temperature measurement. Increasing the temperature can reduce the generation of porosity, but excessively high temperatures or long holding time will result in grain coarsening and cracking, posing difficulties in accurately controlling the microstructure. Additionally, the shape and modeling requirements of materials for SPS diffusion bonding are relatively high. The sintering method (furnace size and pressurization method) determines that large and complex structures of welded parts are challenging to achieve.
The main challenge in EBW and LBW of tungsten alloy and molybdenum alloy are grain coarsening caused by high energy input, segregation of MoO2 particles and stress concentration at grain boundaries. Selecting suitable intermediate layer materials, controlling welding parameters, and optimizing the welding process can inhibit cracks, porosity and the generation of intermetallic compounds. Many existing studies lack systematic research and theoretical guidance for the corresponding relationship between welding parameters and intermediate layer matching.
The study of tungsten/molybdenum alloy doping mainly focuses on the addition of La2O3, Al2O3, ZrO2 and Y2O3 particles, as well as metal carbide TiC and ZrC particles. However, excessively high doping content is prone to agglomeration, leading to increased porosity and cracks. How to obtain uniform doping and add an appropriate amount of doping to achieve high-temperature mechanical properties of the joints, as well as their microstructural features and strengthening effects, is rarely reported.
1) Research on brazing tungsten/molybdenum alloys should broaden the scope of brazing materials to develop new, excellent brazing alloys beyond the Ti-Ni base for tungsten/molybdenum alloy brazing. Additionally, incorporating new elements (Zr, Cr, Cu, etc) and implementing diffusion barrier layers can further strengthen the HAZ region on the molybdenum side, achieving joints with superior mechanical properties.
2) In terms of SPS diffusion welding of tungsten and molybdenum alloys, future research should focus on two main aspects. Firstly, optimizing the welding process through more advanced temperature control and testing systems enable more precise control of the microstructure, thus ensuring densification and grain refinement during the welding process. Secondly, improving the equipment pressure application method allows welding of complex structural components.
3) Further research on EBW and LBW of tungsten/molybdenum alloys should focus on grain refinement and the inhibition of brittle compound formation. A comprehensive review of the welding process, including welding parameters and interlayers, is necessary. Additionally, appropriate preheating and post-heating techniques combined with doping and composite alloying methods can enhance the strength of the FZ region while ensuring the strength of the HAZ region.
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