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Dissimilar junctions between the zirconium alloy (Zy-4) and 304L stainless steel (SS) are prepared via two bonding processes: solid-phase diffusion at T 1  = 1223 K and in transient liquid phase (TLP) at T 2  = 1293 K and T 3  = 1323 K for an identical isothermal hold time of 2700 s. The formed layers and phases at the interface were characterised by the combination of EDS-EBSD-ESEM, EPMA and X-RD and impact fracturing tests. The Zy-4/SS interface is formed of three layers containing Cr-rich α-Fe and Zr(Fe,Cr) 2  and Zr 2 (Fe,Ni) intermetallic compounds. We establish the relationship between the interface microstructures and hot cracking formation which are of thermo-mechanical and solidification origin. The knowledge of the solidification path of the TLP obtained in LIII layer at T 2  and T 3  makes it possible to explain the formation of micro-pores. The fracture is for both bonding processes, takes place in the brittle mode, of the intergranular type by cleavage and is in the LIII layer of the junction.

Microstructures and hot cracking formed at the interface of Zircaloy-4/stainless-steel-304L junctions