Abstract
High corrosion-resistance aluminum alloy joint obtained by filler metal containing Sn at relatively low temperatures is a longstanding goal for electronic products. In this research, 6063Al alloys was joined by a novel ultrasonic-assisted diffusion bonding via liquid phase and solid phase synergistic diffusion. It was performed via a hypereutectic interlayer of Zn-30Sn at 360 ℃ to joining 6063Al, obtaining a Zn-Al eutectoid structures joint. By the ultrasonic vibrating, the breaking of oxide film, the diffusing of liquid and solid state had been occurring in sequence during the joining process. It resulted in a series of diffusing phase transitions from “η-Zn phases + Sn-Zn eutectic structures” to “Zn-Al eutectoid structures + η-Zn phases”, and finally to “full Zn-Al eutectoid structures”, which were driven by the grain boundary penetration and chemical potential, respectively. The joints possessed a higher strength than the base metal. The joints with Zn-Al eutectoids have a better corrosion resistance that the tensile strength reduced 37.3% after a corroding of 72 h in 3.5 wt% NaCl solution in comparison with the soldered joints. Finally, the mechanism of ultrasonic accelerated diffusion, joint formation process and mechanism of improving corrosion resistance were discussed in detail.
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