Abstract
Transient liquid phase diffusion bonding of an aluminum metal matrix composite with 15 wt.% Mg2Si reinforcement particles using Cu powder interlayer at 560 °C for different bonding times has been studied. Three different zones were identified at the bonding line: athermally solidified zone, isothermally solidified zone and base metal. By increasing the bonding time, due to the diffusion of copper to the substrate, the width of the athermally solidified zone decreased, became more homogenous and the amount of intermetallic phase (CuAl2) decreased. Therefore, the shear strength increased to a maximum of 60 MPa for the samples with a holding time of 5 h at the bonding temperature.
Highlights
Aluminum alloys are substantially employed in the automotive industry and aerospace due to formability, superior strength-to-weight ratio, corrosion resistance, and recyclability and castability [1,2]
Efforts have been made to develop aluminum metal matrix composite (AlMMC) by adding different types of reinforcement particles such as SiC and Al2O3 to improve the mechanical properties of MMC [3–5]
The emergence of using additive manufacturing processes such as selective laser melting (SLM) or selective laser sintering (SLS) processes changed the traditional way of manufacturing of metallic components [6–9]; traditional manufacturing processes such as casting, forging and extrusion are still preferable techniques to produce aluminum alloys and AlMMC parts due to low absorptivity of the laser beam, tenacious oxide films, and low boiling point of aluminum
Summary
Aluminum alloys are substantially employed in the automotive industry and aerospace due to formability, superior strength-to-weight ratio, corrosion resistance, and recyclability and castability [1,2]. The substantial need to use lightweight materials in aerospace and automotive industries has prompted research to improve the mechanical properties of lightweight alloys such as aluminum and magnesium In this sense, efforts have been made to develop aluminum metal matrix composite (AlMMC) by adding different types of reinforcement particles such as SiC and Al2O3 to improve the mechanical properties of MMC [3–5]. In solid state diffusion bonding of AlMMC, the presence of a tenacious and stable aluminum oxide layer on the surface could inhibit metal-to-metal contact; resulting in an improperly joined interface Overcoming this problem needs the application of high pressure to disrupt the oxide layer and force the surfaces into close contact, causing excessive plastic deformation and losing dimension accuracy [5]. The TLP bonding process using copper powder was adopted to join the Al/Mg2Si composite and the role of holding time on microstructure evolution and mechanical properties were investigated
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