The Influence of Time, Atmosphere and Surface Roughness on the Interface Strength and Microstructure of AA6061–AA1050 Diffusion Bonded Components

Michael Ben-Haroush, Brigit Mittelman, Roni Shneck, Elad Priel

Research output: Contribution to journalArticlepeer-review

2 Scopus citations

Abstract

Diffusion bonding experiments followed by tensile testing were conducted on cylindrical pairs of AA6061–AA1050 aluminum alloys. The influence of bonding time, atmosphere and surface roughness on the resulting interface strength was studied. Metallurgical characterization was performed to study the quality of the bonded interface for different process conditions, and also to investigate the process of oxide formation on the specimen surface. Finite element analysis of the bonding experiments was used to study the thermo-mechanical fields during the bonding process. Using a cohesive zone approach for modelling the bonded interface, the bond strength for the different process parameters was quantified. The results demonstrate that high bond strength can be obtained even for specimens bonded in an air furnace, provided the surface roughness is low. When the surface roughness increases, specimens bonded in air show a reduction in interface strength, which is not observed for specimens bonded in vacuum. Inspection of the bonded interface suggests that this reduction in interface strength can be attributed to oxidation and pockets of air trapped between the asperities of the contact surface, which hinder diffusion and plastic flow.

Original languageEnglish
Article number769
JournalMaterials
Volume16
Issue number2
DOIs
StatePublished - 1 Jan 2023

Keywords

  • Al alloys
  • FE
  • bonding strength
  • oxide film
  • solid-state diffusion bonding

ASJC Scopus subject areas

  • Condensed Matter Physics
  • General Materials Science

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