Effects of surface roughness on the diffusion bonding of Al alloy 6061 in air

The effect of surface roughness on the properties of Al6061 joints fabricated by diffusion bonding in air at 450°C was studied. It was found that rougher surfaces yield superior ultimate tensile strength and linearized bonded ratio. Joints with ultimate tensile strength comparable to that of bulk metal were obtained for holding times of 75 min using rougher surfaces; however, the maximum linearized bonded ratio obtained was only about 75%. Incomplete bonding was attributed to air entrapment along the bond interface. This was due to good bonding occurring at the periphery of the bonded specimens during the early part of the bonding process.