Developing Temperature–Time and Pressure–Time diagrams for diffusion bonding AZ80 magnesium and AA6061 aluminium alloys

The principal difficulty when joining magnesium (Mg) and aluminium (Al) lies in the existence of formation of oxide films and brittle intermetallic in the bond region. However diffusion bonding can be used to join these alloys without much difficulty. In this investigation, an attempt was made to develop Temperature–Time and Pressure–Time diagrams for diffusion bonding of AZ80 magnesium (Mg) and AA6061 aluminium (Al) dissimilar materials. The bonding quality of the joints was checked by microstructure analysis and lap shear tensile testing. Based on the results Temperature–Time and Pressure–Time diagrams were constructed. These diagrams will act as reference maps for selecting appropriate diffusion bonding process parameters to join AZ80 magnesium alloy and AA6061 aluminium alloy without trial experiments.