Large-scale diffusion bonding of aluminium alloy without interlayers: Mechanical performance and interface quality

Science and Technology of Welding & Joining 2026

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Authors: Da-Wei Liu, Yuan-Ting Lin, Wei-Shuai Lin, Jiann Lin Chen, Shyong Lee, Shu‐Han Hsu, Chun-Lin Chu, Chun-Lin Chu
DOI: 10.1177/13621718251405031
Cited by: 0
References: 9

Abstract

Genuine diffusion bonding (DB) of aluminium alloys on a practically usable scale has yet to be fully demonstrated for industrial applications. This study presents the successful fabrication of large-sized DB samples of AA6061 aluminium alloy without interlayers and evaluates the mechanical integrity of the bonded interfaces through tensile and shear tests. Notably, tensile testing – seldom performed in previous literature due to limited sample dimensions – was conducted on specimens extracted from the diffusion-bonded assemblies. The results reveal that under optimised process conditions, the bonded interface can attain mechanical performance comparable to the monolithic parent alloy, indicating near-100% bonding efficiency.

Fields of Study & Subjects

Aluminum Alloys Composites Properties Advanced Welding Techniques Analysis Microstructure and mechanical properties

Publication details

Journal / source
Science and Technology of Welding & Joining
Volume
31
Issue
2
Pages
99–107
Publication date
5 January 2026
Language
EN