To solve the problem of poor weldability between TiAl-based and Ti₂AlNb-based alloys, spark plasma diffusion bonding was employed to join a TiAl alloy and a Ti₂AlNb alloy with a pure Ti foil as interlayer at 950 °C/10 KN/60 min. After welding, slow cooling was carried out at a rate of 5 °C/min, followed by homogenization at 800 °C for 24 h. The microstructural evolution and elemental migration of the joint were analyzed via a scanning electron microscope equipped with an energy dispersive spectrometer, while the mechanical properties of the joint were assessed via microhardness and tensile tests. The results show that the spark plasma diffusion bonding formed a joint of TiAl/Ti/Ti₂AlNb without microcracks or microvoids, while also effectively protecting the base metal. Before heat treatment, the maximum hardness value (401 HV) appeared at the Ti₂AlNb/Ti interface, while the minimum hardness value (281 HV) occurred in the TiAl base metal. The tensile strength of the heat-treated joint at room temperature was measured to be up to 454 MPa, with a brittle fracture occurring in the interlayer. The tensile strength of the joint at 650 °C was measured to be up to 538 MPa, with intergranular cracks occurring in the TiAl base metal.

The mechanical interlocking structure design was applied to the transient liquid phase bonding of GH4169 based on the bionic structure of the beetle’s exoskeleton. The microstructures and tensile fracture behaviors of the joints with circular, elliptical, and isosceles-trapezoid interlocking structures were investigated. The results show that the mechanical properties of the joint can be improved through bio-inspired structural design. Among them, the elliptical interlocking structure exhibits the most significant strengthening effect. The elliptical interlocking structure can effectively hinder crack propagation, resulting in the highest strength, plasticity, and stress-rupture lifetimes of the joint. The tensile strength of the joint with elliptical interlocking structure at room temperature and 923 K was 1006 MPa and 905 MPa, respectively. Under 690 MPa/923 K, the stress-rupture lifetime of the joint with elliptical structure reached 28.93 h.