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<p>This study investigated diffusion bonding of large 6061 aluminum alloy plates in air using an Al-7Si-26Ge interlayer. Optimal parameters were a pressure of 3&#xa0;MPa, temperature of 510&#xa0;°C, and holding time of 90 minutes, achieving a maximum joint shear strength of 60.13&#xa0;MPa. Microstructural analysis revealed a distinct interlayer zone containing Si-Ge solid solutions and diffusion zones with Al-Mg-Ge intermetallic compounds. The bonding mechanism began with the rupture of the native oxide film under heat and pressure. A Al-Ge eutectic liquid formed in the interlayer, enabling Ge diffusion into the base metal. Subsequently, a similar liquid phase formed at the base metal surface, displacing the fractured oxide, which was expelled by capillary action. Concurrent interdiffusion of Ge and Mg atoms occurred, followed by isothermal solidification to form a homogeneous joint.</p>

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Research on Diffusion Bonding Process and Joining Mechanisms of 6061 Aluminum Alloy in Ambient Atmosphere

  • 期刊论文

  • 发表日期：

    2026年2月11日

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  • Xiaolong Wan,
  • Weimin Long,
  • Quanbin Lu,
  • Yuanyuan Dong,
  • Hao Si,
  • Dashuang Liu

摘要

This study investigated diffusion bonding of large 6061 aluminum alloy plates in air using an Al-7Si-26Ge interlayer. Optimal parameters were a pressure of 3 MPa, temperature of 510 °C, and holding time of 90 minutes, achieving a maximum joint shear strength of 60.13 MPa. Microstructural analysis revealed a distinct interlayer zone containing Si-Ge solid solutions and diffusion zones with Al-Mg-Ge intermetallic compounds. The bonding mechanism began with the rupture of the native oxide film under heat and pressure. A Al-Ge eutectic liquid formed in the interlayer, enabling Ge diffusion into the base metal. Subsequently, a similar liquid phase formed at the base metal surface, displacing the fractured oxide, which was expelled by capillary action. Concurrent interdiffusion of Ge and Mg atoms occurred, followed by isothermal solidification to form a homogeneous joint.