Developing diffusion bonding windows for joining AZ31B magnesium–AA2024 aluminium alloys

The principal difficulty when joining Magnesium (Mg)–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 processing windows for effective diffusion bonding of Mg–Al dissimilar materials. The bonding quality of the joints was checked by microstructure analysis and lap shear tensile testing. Based on the results, diffusion bonding windows were constructed and they will act as reference maps for selecting appropriate process parameters to get good quality bonds.