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It is difficult to achieve good quality diffusion bonded joints in Al alloys due to the stability of the oxide film on the surface of these alloys. Mg is the most effective element for reducing surface oxide films at the bonded interface of Al and its alloys. It has been demonstrated that Mg additions are effective in breaking down the oxide layer at the bonded interface by a reduction reaction that takes place during the diffusion bonding process under a high vacuum. In order to clarify the effect of environmental pressure (3×10-3 Pa, 3 Pa, 105 Pa) on the reduction reaction at the bonded interface, 3003 Al alloys containing varying amounts of Mg (0, 0.3, 0.6, 1.2, 2.5, 5 mass%) were diffusion bonded. The mechanical properties of the joints were improved by the reduction reaction of Mg. The optimum Mg level for improving the joints was determined to be 0.3-1.2% and 0.3-0.6% at environmental pressures of 3×10-3 Pa and 3 Pa, respectively. 3003 Al alloys with Mg added in the range of 0.3-0.6% were well bonded regardless of the vacuum pressure.

The Effect of Varying Mg Levels on the Diffusion Bonding of 3003 Aluminum Alloys