Transient liquid phase diffusion bonding of Al 6061 containing 15 vol.-%
alumina particles was carried out as a function of interlayer thickness. Electrodeposited
Ni coatings containing 18 vol.-% nanosized alumina particles with thickness
ranging from 1 to 13 μm was used as the interlayer. Joint formation was
attributed to the solid state diffusion of Ni into the Al 6061 metal matrix
base metal followed by eutectic formation, base metal dissolution and isothermal
solidification at the joint interface. Examination of the joint region using
scanning electron microscopy, wavelength dispersive spectroscopy and X-ray
diffraction showed the formation of intermetallic phases such as AlFe3Si,
Ni17Al3·9Si5·1O48
and Ni3Si within the joint zone. The results indicated that a maximum
joint strength of 92% of the base metal shear strength can be obtained
if an 11 μm thick Ni–Al2O3 nanocomposite coating
is used as the interlayer.
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