Influence of Effective Physical Contact Area on Microstructure and Mechanical Properties of Diffusion-Bonded TC4/1060Al Joints

  • Guoqiang Luo
  • Jiayu He
  • Zhenfei Song
  • Jian Zhang
  • Mei Rao
  • Jianjun Mo
  • Yiyu Wang
  • Qiang Shen
  • Lianmeng Zhang


In the present study, dissimilar TC4 alloy and 1060Al alloy were successfully diffusion-bonded at a very low temperature about 410 °C by improving the effective physical contact area. A sound joint with a crack-free interface and a high shear strength (128 MPa) is obtained with a combination of TC4 surface roughness of 109.90 μm (Sa) and 1060Al surface roughness of 101.43 μm (Sa), and customized parallel surface scratches. Under this condition, the two parent metals share the largest contact area during the physical contact stage of diffusion bonding process, which is consistent with the theoretical calculation. The results show that no Ti-Al binary intermetallic compounds are observed at the interface of the joints. The maximum shear strength of the joint reaches 128 MPa with optimized bonding parameters (410 °C for 120 min with a pressure of 20 MPa), which is higher than the shear strength of 1060Al (80 MPa) base metal. The fractography analysis indicates the joints failed with a ductile fracture at the 1060Al side.


1060Al alloy diffusion bonding microstructure physical contact area shear strength TC4 alloy 



The authors gratefully acknowledge the sponsorship from the National Natural Science Foundation of China (No. 51572208 and 51521001), 111 Project (B13035), Nature Science Foundation of Hubei Province (2016CFA006), and Joint Fund (No. 6141A02022209). The authors would also like to thank Tiffany Jain, M.S., from Liwen Bianji, Edanz Group China (, for editing the english text of a draft of this manuscript.

Authors’ Contribution

Guoqiang Luo, Jiayu He, Mei Rao, Jianjun Mo, Yiyu Wang, Qiang Shen, and Lianmeng Zhang conceived and designed the experiments; Jiayu He performed the experiments; Jiayu He, Zhenfei Song, and Jian Zhang analyzed the data; Jiayu He, Guoqaing Luo, Jian Zhang, and Mei Rao wrote the paper.

Conflict of Interest

All authors declare that they have no conflict of interest.


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Copyright information

© ASM International 2019

Authors and Affiliations

  • Guoqiang Luo
    • 1
  • Jiayu He
    • 1
  • Zhenfei Song
    • 2
  • Jian Zhang
    • 1
  • Mei Rao
    • 1
  • Jianjun Mo
    • 2
  • Yiyu Wang
    • 3
  • Qiang Shen
    • 1
  • Lianmeng Zhang
    • 1
  1. 1.State Key Laboratory of Advanced Technology for Materials Synthesis and ProcessingWuhan University of TechnologyWuhanPeople’s Republic of China
  2. 2.Institute of Fluid PhysicsChina Academy of Engineering PhysicsMianyangPeople’s Republic of China
  3. 3.Department of Chemical and Materials EngineeringUniversity of AlbertaEdmontonCanada

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