Welding in the World

, Volume 57, Issue 4, pp 523–539 | Cite as

Development of processing windows for diffusion bonding of aluminium/magnesium dissimilar materials

  • V. BalasubramanianEmail author
  • M. Joseph Fernandus
  • T. Senthilkumar
Research Paper


This paper presents the procedures involved in constructing the diffusion bonding windows such as temperature–time and pressure–time diagrams for effective diffusion bonding of aluminium alloy and magnesium alloys. Empirical relationships were developed to predict the lap shear strength of diffusion bonded joints of aluminium (Al) alloy (AA6061) and magnesium (Mg) alloys (AZ31B, AZ61A, AZ80), incorporating diffusion bonding parameters such as bonding temperature, bonding pressure, holding time and surface roughness of the materials to be joined. Response surface methodology was applied to optimise the diffusion bonding parameters to attain the maximum shear strength of the joint. Relationship was established between weight percentage of Al content in Mg alloys and optimised diffusion bonding parameters. The developed processing windows can be used as reference maps to the design and welding engineers for selecting appropriate diffusion bonding parameters to get good quality bonds for Al and Mg alloys.


Diffusion bonding Aluminium Magnesium Shear strength Microstructure 



The authors are grateful to the Department of Manufacturing Engineering, Annamalai University, Annamalai Nagar, India for extending the facilities of metal joining and Material Testing to carry out this investigation. The authors also wish to express their sincere thanks to Dr. S. Rajakumar, Assistant Professor, Dept. of Manufacturing Engineering, Annamalai University for helping in statistical analysis.


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Copyright information

© International Institute of Welding 2013

Authors and Affiliations

  • V. Balasubramanian
    • 1
    Email author
  • M. Joseph Fernandus
    • 2
  • T. Senthilkumar
    • 3
  1. 1.Center for Materials Joining and Research (CEMAJOR), Department of Manufacturing EngineeringAnnamalai UniversityAnnamalainagarIndia
  2. 2.Department of Mechanical EngineeringSrinivasan Engineering CollegePerambalurIndia
  3. 3.Department of Mechanical EngineeringAnna University Chennai Tiruchirappalli RegionTiruchirappalliIndia

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