Effect of interlayer composition on the microstructure and strength of diffusion bonded Mg/Al joint

The diffusion bonding of Mg and Al alloys with different interlayer compositions was investigated, where the interlayer was prepared through hot dipping technique in pure Zn, Zn–8Al and Zn–5Al baths, respectively. By means of microstructure characterization and strength measurement, it is found that the interlayer obtained in Zn–5Al bath led to the formation of interface microstructure composed of mini Al-rich particles dispersed in MgZn₂ phase, this kind of phases constituent decreases the risk of embrittlement of entire diffusion bonding joint and benefits its mechanical performance greatly.