Effect of Al thin film and Ni foil interlayer on diffusion bonded Mg–Al dissimilar joints

Diffusion bonded Mg–Al joints with and without an interlayer were produced. An Ni foil interlayer eliminated the formation of Mg–Al intermetallic compounds, while addition of an Al thin film to the interlayer improved the properties of the Mg–Ni intermetallic compounds. The shear strength of the joints was improved by the addition of the Ni foil and Al thin film interlayer.