Diffusion welding involves minimal pressurization, but relatively high temperatures and long periods of time. This article discusses the process variants of diffusion welding: solid-phase and liquid-phase processes. It describes the diffusion welding of carbon and low-alloy steels, high-strength steels, stainless steels, and aluminum-base alloys. The article provides a discussion on dissimilar metal combinations, such as ferrous-to-ferrous combinations, nonferrous-to-nonferrous combinations, ferrous-to-nonferrous combinations, and metal-ceramic joining.

Conventional high-strength aluminum alloys produced via powder metallurgy (P/M) technologies, namely, rapid solidification (RS) and mechanical alloying (mechanical attrition) have high strength at room temperature and elevated temperature. This article focuses on the metallurgy and weldability of dispersion-strengthened aluminum alloys based on the aluminum-iron system that are produced using various RS-P/M processing techniques. It describes weldability issues related to weld solidification behavior, the formation of hydrogen-induced porosity in the weld zone, and the high-temperature deformation behavior of these alloys, which affect the selection and application of fusion and solid-state welding processes. The article provides specific examples of material responses to welding conditions and highlights the microstructural development in the weld zone.

This article provides an overview of the types of weld discontinuities that are characteristic of specialized welding processes. These welding processes include electron-beam welding, plasma arc welding, electroslag welding, friction welding, resistance welding, and diffusion welding. The article also describes the common inspection methods used to detect these discontinuities.