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<p>The interaction between Mg, Si, and Al<sub>2</sub>O<sub>3</sub> during hot isostatic pressing diffusion bonding of aluminum alloy 6061 (AA6061) plates was investigated through thermodynamic calculations and experimental microstructural characterization. Thermodynamic calculations as functions of temperature, pressure, and composition revealed that the interaction among Mg, Si, and Al<sub>2</sub>O<sub>3</sub> yields Mg<sub>2</sub>Si and either MgO + Al or MgAl<sub>2</sub>O<sub>4</sub> + Al, facilitating the reduction of Al<sub>2</sub>O<sub>3</sub> and allowing Al/Al metallic bonds to form. Total pressure variation had a negligible influence on the oxygen partial pressure, and consequently, the reaction product formation. Oxygen partial pressure variation as a function of temperature and initial amount of Al<sub>2</sub>O<sub>3</sub> determined the formation of either MgO or MgAl<sub>2</sub>O<sub>4</sub>. Experimental Hot Isostatic Pressure (HIP) bonding at 723&#xa0;K and 833&#xa0;K under a constant pressure of 1017&#xa0;atm documented the cooling rate-dependent formation of β–Mg<sub>2</sub>Si precipitates. High-resolution transmission electron microscopy imaging and selected area electron diffraction patterns verified the formation of β–Mg<sub>2</sub>Si and MgO at the interface but did not detect MgAl<sub>2</sub>O<sub>4</sub>. Findings from this study clarify the role of thermochemical interactions in oxide disruption and bonding mechanisms during HIP diffusion bonding of AA6061 and provide guidance for optimizing joining processes for monolithic nuclear fuel assemblies.</p>

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Understanding Oxide–Metal Interactions During Hot Isostatic Pressing to Diffusion Bond Aluminum Alloy 6061 Plates

  • 期刊论文

  • 发表日期：

    2025年11月3日

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  • Jason Schulthess,
  • Shayndel Pido,
  • Nima Noei,
  • Paria Gharavi,
  • Yongho Sohn

摘要

The interaction between Mg, Si, and Al2O3 during hot isostatic pressing diffusion bonding of aluminum alloy 6061 (AA6061) plates was investigated through thermodynamic calculations and experimental microstructural characterization. Thermodynamic calculations as functions of temperature, pressure, and composition revealed that the interaction among Mg, Si, and Al2O3 yields Mg2Si and either MgO + Al or MgAl2O4 + Al, facilitating the reduction of Al2O3 and allowing Al/Al metallic bonds to form. Total pressure variation had a negligible influence on the oxygen partial pressure, and consequently, the reaction product formation. Oxygen partial pressure variation as a function of temperature and initial amount of Al2O3 determined the formation of either MgO or MgAl2O4. Experimental Hot Isostatic Pressure (HIP) bonding at 723 K and 833 K under a constant pressure of 1017 atm documented the cooling rate-dependent formation of β–Mg2Si precipitates. High-resolution transmission electron microscopy imaging and selected area electron diffraction patterns verified the formation of β–Mg2Si and MgO at the interface but did not detect MgAl2O4. Findings from this study clarify the role of thermochemical interactions in oxide disruption and bonding mechanisms during HIP diffusion bonding of AA6061 and provide guidance for optimizing joining processes for monolithic nuclear fuel assemblies.