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<p>The study focuses on optimizing process variables, including Bonding Temperature (BT), Holding Time (HT) and Bonding pressure (BP) for the diffusion bonding of AA2219/Ti-2.5Sn-5Al dissimilar alloy joints. A reliable mathematical model was developed to estimate interfacial hardness and lap-shear strength in diffusion-bonded Al/Ti joints using a response surface methodology (RSM) in Box-Behnken design (BBD) method. Optimal bonding conditions of 544&#xa0;°C, 15&#xa0;MPa, and 59&#xa0;min resulted in an interfacial hardness of 139 HV1 and a lap shear strength of 48.9&#xa0;MPa. Analysis of variance (ANOVA) identified bonding temperature as the most influential factor affecting both responses. Scanning electron microscopy (SEM) confirmed a defect-free interface without cavities or cracks, ensuring bonding integrity. These findings demonstrate the effectiveness of RSM in optimizing DB for dissimilar metals and achieving high-quality joints.</p>

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Investigations on Effect of Diffusion Bonding Process Parameters on AA2219/Ti-2.5Sn-5Al Alloys Dissimilar Joints Using Response Surface Methodology

  • 期刊论文

  • 发表日期：

    2025年6月25日

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  • G. C. Tejaswini,
  • B. Lathashankar,
  • R. Suresh,
  • N. G. Siddesh Kumar

摘要

The study focuses on optimizing process variables, including Bonding Temperature (BT), Holding Time (HT) and Bonding pressure (BP) for the diffusion bonding of AA2219/Ti-2.5Sn-5Al dissimilar alloy joints. A reliable mathematical model was developed to estimate interfacial hardness and lap-shear strength in diffusion-bonded Al/Ti joints using a response surface methodology (RSM) in Box-Behnken design (BBD) method. Optimal bonding conditions of 544 °C, 15 MPa, and 59 min resulted in an interfacial hardness of 139 HV1 and a lap shear strength of 48.9 MPa. Analysis of variance (ANOVA) identified bonding temperature as the most influential factor affecting both responses. Scanning electron microscopy (SEM) confirmed a defect-free interface without cavities or cracks, ensuring bonding integrity. These findings demonstrate the effectiveness of RSM in optimizing DB for dissimilar metals and achieving high-quality joints.