Zn Interlayer Research Articles

Dynamic behaviors of interfacial oxides and elements during the ultrasonic-assisted diffusion bonding of 6063Al alloys

Efficiently breaking the oxide layer and rapidly diffusing of elements at low-temperature has been a longstanding goal in the diffusion bonding (DB) of Al alloys. To break the interfacial oxide layers and accelerate atomic diffusion, ultrasound energy was introduced during the DB of 6063Al. A full Zn–Al eutectoid joint was manufactured via a pure Zn interlayer at 360 °C in atmospheric by an ultrasonic-assisted diffusion bonding (U-DB) at only an ultrasonic vibration of10 min. During U-DB, brittle cracks were formed in the interfacial oxide layers due to high strain rate induced by ultrasonic action. Zn diffused into Al alloy through the brittle cracks in oxide layers via “subcutaneous diffusion,” forming a Zn–Al eutectoid diffusion region between the Al alloy and oxide layer. The oxide fragments irregularly migrated to the center of the joint due to Kirkendall effect and ultrasonic action, finally dispersed in the bonded metal. The bonded metal finally transformed as a full Zn–Al eutectoid phase after consuming interlayer. The shear strength of the Zn–Al eutectoid joint reached 82.6 MPa. The Zn–Al mutual diffusion coefficient of U-DB at 360 °C was ∼0.6 μm2/s, which was about 20 times higher than the thermal diffusion coefficient under same temperature condition. Additionally, the mechanism of ultrasonic-assisted diffusion based on the strain-driven diffusion mode was discussed in detail.

Advancements in joining Al-Zn-TiC-Mg composites using friction stir welding process: Influence of traverse speed

In this article, dissimilar magnesium and aluminum alloys were welded with a Zn interlayer and TiC nanoparticles by friction stir welding. Optimal joining conditions were achieved by a combination of three traverse speeds (30, 45, and 60 mm/min) and constant rotational speeds (1050 rpm). The best microstructure evolution and mechanical properties were achieved for specimens joined at rotational and traverse speeds of 1050 rpm and 45 mm/min, respectively. The grain size decreases as the traverse speed increases from 30 to 45 mm/min due to a reduction in heat input, an improvement in reinforcing distribution, and high intermixing of materials, then increases from 45 to 60 mm/min due to inadequate heat input for recrystallization process. It was shown that the TiC particles play a prominent role in the microstructure modification and enhance mechanical properties of weld samples while the Zn foil interlayer plays a vital in avoiding the formation of Al-Mg IMC phases. The obtained result under optimal welding parameters indicates that MgZn2, Mg-Al-Zn compounds, Mg and Al solid solution, were the main detected common phases in the stir zone instead of the brittle and hard Al-Mg IMCs formation. The average hardness values of 232 Hv were achieved, while the strength of the weld specimen experiences the 189 MPa value. In addition, a combination of brittle and ductile modes was observed based on the fracture surface of the weld sample after the tensile test.

Dissimilar low-temperature diffusion bonding of copper and titanium using a Zn interlayer: Interfacial microstructure and mechanical properties

In this study, a zinc (Zn) interlayer was applied in the diffusion bonding of pure copper (Cu) and titanium (Ti). The interfacial microstructure evolution and metallurgical reaction mechanisms of Cu/Ti joints with Zn interlayer were investigated by SEM, EDS and TEM. The addition of the Zn interlayer facilitated metallurgical bonding between Cu–Zn and Ti–Zn at low temperatures. The shear strength of joints exhibited a gradual increase followed by a sharp decline as the bonding temperature increased. An intimate bonding between Cu and Ti was achieved at 450 °C, and the highest average shear strength of 106.82 MPa was obtained at 490 °C. The weld seam is primarily composed of a β′-CuZn layer, which exhibited excellent plasticity and hindered the formation of brittle Cu–Ti intermetallic compounds. The τ1-Cu2TiZn layer, adjacent to β′-CuZn, demonstrated stronger resistance to crack propagation compared to the brittle TiZn3 and TiZn2 layers. Furthermore, the predominant β′-CuZn layer and τ1-Cu2TiZn layer formed a coherent interface, ensuring a reliable bonding. These results demonstrate that the addition of Zn interlayer is an effective strategy for preparing highly reliable Cu/Ti joints at low temperatures.

Understanding the formation mechanism of SiC/Al joints by U-TLP bonding with the inactive Zn interlayer

The ultrasonic-assisted transient liquid phase (U-TLP) bonding process is extremely fast, which is a great challenge to reveal the inherent mechanisms. Understanding the joint formation mechanism of U-TLP is essential for the joining process design. In this study, the SiC ceramics and 6063Al alloys were joined by U-TLP using a Zn interlayer. The process of removing the oxide film on the base metal involved cracking, flaking off, suspending, and fragmenting. The migration of the eutectic liquid phases frontier was very fast (within 1 s). The relationship between the thickness of the liquid layer and the ultrasonic action time was a power function. The typical microstructure of the SiC/6063Al joints was SiC/amorphous Al2O3/Zn-Al eutectic/ Zn-Al eutectoid/6063Al. The shear strength of SiC/6063Al joints increased with the interfacial bonding ratio and reached up to 27 MPa for the ultrasonic action time of 5 s. The metallurgical bonding at the SiC/bond metal interface was formed through the amorphous Al2O3 transition layer. The formation mechanism of the Al2O3 reaction layer was revealed based on the thermodynamics, kinetics, and acoustics cavitation theory. This will provide a guideline for the future U-TLP process design.

Mechanical properties and corrosion behaviour of dissimilar friction stir-welded Al 7075 and Mg AZ31 alloys with Cd and Zn interlayer

ABSTRACT The objective of present research work is to study joint strength and corrosion behaviour of dissimilar Friction Stir Welding (FSW) of Al 7075 and Mg AZ31 alloys with Cd and Zn interlayer. The FSW process performed at rotational speed 1300 rev min–1 and travel speed 20 mm min−1. The comparative study of mechanical properties and corrosion behaviour of FSW with Cd and Zn interlayers has been attempted for the first time. The result shows that the maximum tensile strength of 129 MPa has been achieved for FSW with Cd interlayer as compared to 85 MPa in the case of FSW with Zn interlayer. The corrosion rate was found in order of FSW with Cd > FSW with Zn > BM AZ31 > BM-7075. It has been concluded that FSW with Zn interlayer resulted in comparatively lower strength and better polarisation resistance than the FSW with Cd interlayer in 3.5 wt-% sodium chloride (NaCl) solution.

Effect of a Zn interlayer on the formation mechanism and mechanical performance of AA6061/DP590 steel resistance riveting welding

This study focuses on the forming mechanism of resistance riveting welding joints of 6061 Al alloy and DP590 steel plate and the effect of adding Zn interlayer on the mechanical properties of the joints. During the piercing stage, the rivet pierces through the Al plate, the Al plate beneath the rivet melts and reacts with the steel, with intermetallic compounds (IMC) generated. Some of the melted Al and IMCs are squeezed onto the side of the rivet. In the process of adding the Zn interlayer, the Zn is gradually incorporated into the melted Al near the rivet during the piercing process. At the welding stage, as the current is increased, the nugget diameter, peak joint load, and energy absorption values gradually increase. The failure mode of the joint changes from an interfacial fracture to pull-out fracture, eventually changing to base material pull-off, as the welding current increases. Compared to joints without Zn addition, joints with Zn addition exhibit a smaller nugget diameter, and narrower IMC layers at the interface. At a welding current of 13 kA, because the failure mode was a shear fracture of the nuggets, the peak joint load of the joints with zinc added decreased by 215 N compared to the unadded ones. On the contrary, when the current increased to 14 kA, the peak joint load of the joints was elevated by 639 N, because the IMC layer and the aluminum plate became the main load-bearing locations.

A novel diffusion bonding of 6063Al based on a mode of diffusion-migrating and suspension-broken of surface oxide film

The breaking of surface oxide film in a technology area of ultrasonic-assisted diffusion joining manufacturing of large-size structure components is a challenge. In this work, a novel method of breaking surface oxide film of Al alloys based on first diffusion-migrating and then suspension-broken was investigated. Diffusion bonding of 6063Al alloys was performed by Zn interlayer at temperature below 400 °C. The oxide film migrated away from the Al alloy base metal by solid phase diffusion at 360 °C, and remained in the joint as a nanoscale oxide film. When temperature increased to 390 °C, the oxide film suspended in the Zn–Al eutectic liquid phase were rapidly broken up into small fragments through an instantaneous ultrasonic action (only 0.3 s). The change of acoustic pressure in the liquid metal proved that the suspended continuous oxide film was broken by the micro-jet acted simultaneously on both sides of oxide film induced by the ultrasonic cavitation effect. Finally, the inter-diffusion between Zn and Al at 360 °C was promoted by a longer holding time to obtain the homogeneous joint composed by Zn–Al eutectoid phase containing oxide fragments, and had a higher strength than the base metal. The breaking of oxide film and joint homogenization were performed under pressure-less condition, which effectively avoided the squeezed-out of the liquid phase. This technology shows a great potential for manufacturing large-size joint of industrial products.

Effect of Hot-Pressing Rate on Interface and Bonding Strength of Mg/Al Composite Sheets with Zn Interlayer

Effect of Hot-Pressing Rate on Interface and Bonding Strength of Mg/Al Composite Sheets with Zn Interlayer

Interfacial Microstructure Evaluation of Precisely Controlled Friction Stir Welding Joints of Al/Mg Dissimilar Alloys with Zn Interlayer

In this study, a penetration-controlled friction stir welding (FSW) technique was employed to lap weld dissimilar Al/Mg alloys, incorporating a Zn interlayer. The joint’s microstructure, interfacial reaction, and phase composition were analyzed through optical microscopy, scanning electron microscopy, and X-ray diffraction. The findings demonstrate the formation of a hybrid joint comprising a FSWed region and a diffusion bonding region achieved by introducing a pure Zn interlayer at the Al/Mg interface. Within the FSWed region, the zinc was fully extruded, leading to favorable interface bonding. In contrast, the diffusion bonding region exhibited an aluminum–zinc diffusion reaction layer, an incompletely reacted zinc layer, and a zinc–magnesium diffusion reaction layer. Notably, no Al-Mg intermetallic compounds (IMCs) were observed in either the FSWed or diffusion bonding regions of the hybrid joint. This study further explored the underlying mechanism behind the joint’s formation.

Microstructural evolution of aluminium in dissimilar A1050/S45C FSW joints by Zn interlayer

This study investigated the microstructural evolution of A1050 stir zones in dissimilar A1050/S45C friction stir-welded joints fabricated with 100- and 200-µm-thick Zn interlayers in addition to a third joint without any interlayer. The dissolved Zn in the A1050 stir zones contributed to its strengthening by forming Al–Zn solid solution. The addition of Zn refined the A1050 grains with many well-defined high-angle grain boundaries. The effect of Zn in the A1050 strengthening and grain refinement becomes apparent with a relatively high content of Zn. The possible precipitation of Zn-rich particles along the A1050 grain boundaries may also contribute to the A1050 stir zone strengthening by retarding the dislocation motion and enhancing the discontinuous dynamic recrystallisation.

Interfacial microstructural evolution and mechanical properties in dissimilar A1050 aluminium and S45C carbon steel friction stir welded joints using Zn interlayers

This study investigated the effect of Zn interlayers on the dissimilar friction stir welding of A1050 pure aluminium and S45C carbon steel. Two joints were made by adding Zn foils of two different thicknesses (100 μm and 200 μm) between the A1050 and S45C base metals in addition to a third joint without any interlayer. The joining experiments were conducted in constant process parameters at tool rotational speed and welding speed of 1500 rpm and 250 mm/min, respectively. The differences in joints microstructure were correlated with their mechanical properties and fracture mode. The results showed that Zn inhibited the growth of the interfacial Al–Fe IMCs, altered their composition and contributed to strengthening the A1050 stir zones by forming Al–Zn solid solution. Compared to the Zn-free joint, the ultimate tensile strength of the joints fabricated with the 100 μm and 200 μm thick Zn interlayers was improved by 14% and 26%, respectively. Also, the brittleness inside their interfacial IMCs was eliminated. As a result, the joints fabricated with Zn interlayers exhibited higher elongation and their fracture occurred at the A1050 instead of the joint interface as in the Zn-free joint. The Zn interlayer is expected to widen the joining process window by minimizing the detrimental effects of the Al–Fe IMCs.

Interfacial microstructure and mechanical properties of Al/steel joints fabricated via thermo-compensated resistance brazing welding with cold spray Zn interlayer

Achieving the effective joining between Al alloy and stainless steel with a large cross-section was meaningful in the significant industry field. For this, the Al/steel dissimilar bimetal materials were manufactured by a novelty hybrid technology, named thermo-compensated resistance brazing welding. The effect of the single Zn foil and the deposited Zn coatings with cold spray technology on the bonding interface, interfacial microstructure, and mechanical properties of the final Al/steel resultant joints were systematically investigated by the relevant analysis method. The results revealed that the obvious reaction layer with main components of Al(s.s) was formed at the Al/steel joints with the single Zn foil as the interlayer. Meanwhile, the introduction of the Zn interlayer improved the temperature field of the joint, which enhanced the lap-shear load of the weld. Besides, the Zn coating was deposited at the top surface of the 304ss substrate as the interlayer to increase joint performance further. The advantage of the pre-deposition formed a better metallurgical bond between the coating and 304ss. The subsequent lap-shear load of the weld was improved with the increase of the Zn coating thickness. The maximum lap-shear load of the final joints reached 2087.6N with a Zn coating thickness of 500 μm and the interfacial structure of the joint was changed: Al alloy, reaction layer I, Al(s.s) + Al2O3, and 304ss from top to bottom. The main composition was Al(s.s) at the reaction layer I between Al alloy and coating.

Migrating behaviors of interfacial elements and oxide layers during diffusion bonding of 6063Al alloys using Zn interlayer in air

The oxide layer on the surface has always been a key obstacle to achieving the diffusion bonding of Al alloys. It is a challenge for performing diffusion bonding without removing oxide layers. Herein, diffusion bonding of Al alloy retaining continuous oxide layers was successfully achieved in the air by a low-temperature and low-pressure diffusion bonding mothed using a Zn interlayer. During the bonding processes, conducted at 360 °C and 3 MPa, Zn diffused into Al through cracks of thin oxide layers to form the joint composed Al/(diffusion layer)/(oxide layer)/(Zn)/(oxide layer)/(diffusion layer)/Al. The diffusion layers were composed of Zn-Al eutectoid, and the oxide layer included nanocrystals and amorphous Al2O3. The shear strength of joints containing continuous oxide layers was about 30 MPa. Interestingly, the migration behavior toward the joint center of the interfacial oxide layers was observed with consuming of the Zn interlayer. The cracking phenomenon, the “subcutaneous diffusion” and the migration behavior of oxide layers were verified and analyzed by the diffusion bonding of anodized 6063Al-6063Al. Subsequently, the dynamic migration mechanism of oxide layers with elements diffusion and bonding interface strengths were discussed in detail. The ability to join Al alloys in the air at low temperatures and low pressure suggests a highly practical and economic method for diffusion bonding.

Influence of the Zn interlayer on the mechanical strength, corrosion and microstructural behavior of friction stir-welded 6061-T6 aluminium alloy and AZ61 magnesium alloy dissimilar joints

To reduce structural weight, the transportation industry needs to join dissimilar Al and Mg alloys. However, due to their different properties, joining dissimilar materials is much harder than joining identical ones. Brittle intermetallic compounds (IMCs) make it difficult to produce strong Al/Mg joints even with friction stir welding (FSW). Mechanical and corrosion properties are important for joint protection over time. Mg-based alloys corrode preferentially in dissimilar Al/Mg joints due to their lower corrosion potential. Consequently, this study introduces a novel interlayer-based strategy to address this issue. Therefore, this study explored the influence of Zn interlayers on the mechanical properties, microstructure, and corrosion behaviors of Al6061-T6 and AZ61 Mg alloy FSW butt joints. A scanning electron microscope, a transmission electron microscope, X-ray photoelectron spectroscopy, X-Ray diffraction, and an energy dispersive spectrometer were used to observe and characterise the microstructures and IMCs formation at the interface of Al/Mg welded joints. In Zn-added FSW joints, finer and better-distributed Mg-Zn IMCs form in place of the brittle Al-Mg IMCs (multilayered structure) observed in Zn free Al/Mg joints. Moreover, the addition of Zn significantly improved the joints' tensile strength through the proper dispersion and distribution of the zinc interlayer in the weld zone. In this way, a tensile strength of 198.85 MPa was attained, 34.17% greater than a Zn free Al/Mg joint. Furthermore, immersion tests revealed that the weld joints of Al/Mg with Zn are more resistant to corrosion than the joints of Al/Mg, resulting in a 12.78% lessening in weight loss compared with a Zn free joint. The reason for that is the Zn interlayer's ability to reduce the dissimilar metal corrosion amid the base materials.

Investigation on the effect of Zn interlayer and process parameters optimisation in the production of Al-SS bimetallic castings

The effect of Zn interlayer on the stainless steel insert in the fabrication of Aluminium-Stainless Steel (Al-SS) Bimetallic casting (BmC) is reported. The design of Experiments was conducted with pouring temperature (680°C–730°C), insert preheat temperature (100°C–400°C) and insert thickness (1–3 mm) as influencing process parameters to produce Al-SS BmC. The maximum bond strength of 25.33 MPa was achieved when the experimental conditions were 705°C pouring temperature, 250°C insert temperature and 2 mm insert thickness. Using Response Surface Methodology (RSM), the interaction between the process parameters has been studied and a second-order polynomial equation was derived for maximising the bond strength. The predicted maximum bond strength using RSM for the above experimental conditions is 26.75 MPa. The output of RSM was given to the Genetic Algorithm (GA) to identify the maximum bond strength at forbidden parametric values. The maximum bond strength predicted using GA by interpolation is 26.87 MPa. However, the three process parametric conditions are 707°C, 277°C, and 1.86 mm respectively for achieving the maximum bond strength in the given Al-SS BmC’s. Experimental validation of the above conditions was conducted and the results obtained confirmed the predicted bond strength value using the GA technique. Spiral morphology due to the formation of Zn10Fe3 intermetallics was observed at the Zn-SS interface when the pouring temperature increased to 730°C and this might have led to the reduced bond strength of BmC than the bond strength achieved at 705°C and 707°C. The formation of the Al-rich and Fe-rich solid solutions as reaction layer between Al and SS without the micro gap around 705°C may contribute to the significant increase in bond strength of produced BmC with different insert temperatures and insert thickness.

Advances in simulation and experimental study on intermetallic formation and thermomechanical evolution of Al–Cu composite with Zn interlayer: Effect of spot pass and shoulder diameter during the pinless friction stir spot welding process

In this study, the pinless friction stir spot welding of aluminum–copper composite with Zn interlayer was analyzed under experimental measurement and finite element method. The role of shoulder diameter, 16, 18, and 20 mm, and the number of spot pass, one to three pass, on microstructure, mechanical properties, and thermal history of weld samples were investigated. Based on the obtained results, there is a good agreement between numerical data and experimental analyses. It was shown that the heat source, due to plastic deformation and friction, increased as the shoulder diameter was increased, whereas the stress distribution in the weld samples was reduced. In addition, the thickness of the Zn interlayer at the joint interface changes when shoulder size increases from 16 to 20 mm, due to high temperature and intermixing between materials. From the microstructure analysis, the grain size in the joint zone gradually decreases as the spot pass increases from 1 to 3. It was concluded that the shoulder diameter of 16 mm with three spot passes showed the best result of 7.45 kN. Depending on X-ray diffraction analyses of the fracture surfaces, three primarily intermetallic phases including the Al2Cu, CuZn5, and CuZn2 were determined in the weld interfaces. Based on finite element method analysis, the axial compressive stresses showed the lowest profile as the shoulder diameter of the tool is 16 mm. Finally, the ductile fracture was detected as the main fracture mechanism for the joint sample with optimal joining conditions.

Microstructural Evolution and Mechanical Properties of Cu/Ti Joints Welded by Ultrasonic Spot-Welding with Zn Interlayer

Cu/Ti dissimilar metals were joined together utilizing ultrasonic spot welding with a Zn interlayer. The threedimensional finite element analysis model was established to simulate the temperature field of the interface of Cu/Ti ultrasonic welding joint under different welding energies. The interface forming, microstructure, and mechanical properties of the Cu/Zn/Ti ultrasonic spot-welded joints were studied systematically. Results showed that the temperature distribution of the interface of the Cu/Zn/Ti ultrasonic welding joint was inhomogeneous, and the temperature of the interface below the indentation reached the highest and decreased gradually to the surrounding. With the increase of welding energy, the maximum temperature and the corresponding high-temperature region of Cu/Zn/Ti joint interface gradually increased. The interface of Cu/Zn/Ti ultrasonic welding joint was well formed, and the thickness was different, and the local position had wavy undulation morphology. When the welding energy was low, the interface microstructure was mainly composed of copper solid solution and titanium solid solution. As the welding energy increased, the microstructure of the joint interface was composed of CuZn compound, copper solid solution and titanium solid solution. When the welding energy was increased to 2000 J, the joint interface microstructure was composed of CuZn, Zn15Ti compound and copper solid solution. In comparison, Cu/Ti joints welded with a Zn interlayer in-between displayed the maximum shearing force about 33.5% greater than those of joints without a Zn interlayer.

Protrusion friction stir spot welding of dissimilar joints of 6061 aluminum alloy/Copper sheets with Zn interlayer

• All of joints generated via PFSSW illustrated a surface approximately free keyhole. • Maximum tensile shear load was obtained 3.2 kN and at 2500 rpm with Zn interlayer. • Brazed zone was affected by tools rotation speed while a dendritic structure was observed at 1600rpm. The dissimilar AA6061/pure Cu sheets were welded using a Zn foil via the protrusion friction stir spot welding (PFSSW) process. It was indicated that increasing the tool rotating speed enhanced the hardness of the stir zone from 55 to 78 HV. Furthermore, the results showed that all of the joints generated by PFSSW failed by IF mode, which can be ascribed to the presence of segregated Cu particles and brittle phases. The sample welded with 2500 rpm exhibited a maximum tensile shear load (3200 N).

Ultrafast ultrasonic-assisted transient liquid bonding Al/Mg in air

We used ultrasonic-assisted transient liquid bonding (UATLP) to join dissimilar Al/Mg alloys with pure Zn interlayer in the air to prevent the formation of AlMg intermetallic compounds (IMCs). The effects of bonding temperature, ultrasonic power, sonotrode pressure, and interlayer thickness on the microstructure and mechanical properties of the bonded joints were studied. Results showed that the addition of Zn interlayer could effectively depress the AlMg IMCs. The oxide layer on the Al substrate is incompletely removed at bonding temperature below 380 °C, the Mg side is bonded by eutectic phase, and the Al side is bonded by diffusion. The joint is characterized by MgZn eutectic (containing ternary IMCs) and IMCs of MgZn and MgZn2 layer. MgZn2 is the weak point of the joint under such a condition, and the joint has shear strength of approximately 20 MPa. The oxide layer on the Al substrate is completely removed when the temperature exceeds 380 °C, the large amount of Al that flows into the joint results in a Mg32(Al,Zn)49 layer adjacent to the Al substrate. The joint gains its maximum strength of 28.4 MPa when thin MgZn2 and discontinuous Mg32(Al,Zn)49 exist adjacent to the Al substrate. High ultrasonic power, large sonotrode pressure, and thin Zn interlayer could reduce the thickness of MgZn2.

Effects of TiZn3 and TiZn16 components on the microstructure and mechanical performance of Ti-6Al-4 V alloy joints formed via ultrasonic assisted brazing using pre-galvanized workpieces

While the use of a Zn interlayer has been demonstrated to reduce the temperature required for joining easily oxidized metal alloys in atmospheric environments, the effects of reactions between the titanium alloy workpieces and the Zn interlayer on the mechanical performance of the finished joints are poorly understood. The present work addresses this issue by evaluating the chemical compositions at the interfaces of pre-galvanized Ti-6Al-4 V alloys joined at 420 °C in an atmospheric environment by ultrasonic-assisted brazing, and relating the observed compositions to the mechanical performances of the joints. The Ti-6Al-4 V alloy workpieces are first wetted by pure Zn using an ultrasonic assisted hot dip galvanizing (U-HDG). The obtained ultrasonic excitations are demonstrated to destroy the oxide film on the surfaces of the Ti-6Al-4 V workpieces and promote reactions between Ti and Zn at the interfaces. The plating of Zn on the workpiece surfaces is demonstrated to be realized by the formation of intermetallic compounds (IMCs) comprising a uniform TiZn3 layer in contact with the Ti-6Al-4 V surface, followed by a mixed TiZn3 + TiZn16 layer and a η-Zn layer at the outer surface. Application of the ultrasonic-assisted brazing process is demonstrated to maintain uniform TiZn3 layers next to the Ti-6Al-4 V surfaces, while the concentration of the TiZn16 phase near the midpoint of the joints increases with increasing ultrasonic treatment time (UST) from 5 s to 20 s, and the corresponding concentration of the η-Zn phase decreases. The results of mechanical testing demonstrate that the shear strength of the joint obtained with a TiZn3 layer thickness of 8–12 μm and a UST of 10 s is 210 MPa, which is 3.55 times greater than that obtained for joints processed without pre-galvanization.