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

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 q...

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Bibliographic Details
Published in:Materials 2023-01, Vol.16 (2), p.769
Main Authors: Ben-Haroush, Michael, Mittelman, Brigit, Shneck, Roni, Priel, Elad
Format: Article
Language:English
Subjects:
Air furnaces
Air pockets
Aluminum alloys
Aluminum base alloys
Bonding strength
Deformation
Diffusion welding
Finite element method
Inspection
Interfacial strength
Intermetallic compounds
Mechanical properties
Metallurgical analysis
Oxidation
Physical properties
Plastic flow
Process parameters
Shear strength
Solids
Surface roughness
Tensile tests
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Summary: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.
ISSN:1996-1944
1996-1944
DOI:10.3390/ma16020769