Diffusion bonding of alumina using interlayer of mixed hydride nano powders

In this study, mixed hydride/alanate nano powders in the Al–Mg system were used as the interlayer for low temperature diffusion bonding of dense alumina parts. Decomposition of hydride nanopowders at bonding temperatures in-situ formed metals and alloys nano particles with oxide free surfaces and high sinter-ability in the interlayer. Nano powders sintering behavior in the interlayer and formation of compounds in the reaction layer during diffusion bonding were studied. Mixture of 50–50 M ratio of AlH3 and Mg(AlH4)2, as the interlayer improved bond strength of the joints. Diffusion bonding products were formed in the MgO–Al2O3 spinel system with different stoichiometries. Bond strength improved up to 202 MPa by induction hot pressing alumina parts at low bonding temperature of 400 °C under pressure of 20 MPa during 30 min bonding period.