Accessible Requires Authentication Published by De Gruyter July 5, 2017

Equal-strength precision diffusion bonding of AA6063 aluminum alloy with the surface passivated by a self-assembled monolayer

Hao Zhang, Jing-Long Li, Chang-Sheng Wang, Jiang-Tao Xiong and Fu-Sheng Zhang


Precision diffusion bonding of aluminum alloy requires good mechanical properties and very low deformation. However, oxidation lowers the quality of the joint. This paper used a self-assembled monolayer, 1-hexyl mercaptan, on the aluminum surface to prevent the secondary oxidation after pre-bonding treatment. An AA6063/Ni/AA6063 sandwich structure joint was intentionally designed and bonded to characterize the effect of the self-assembled monolayer. AA6063/AA6063 joints were diffusion bonded, in which three different pre-bonding surface treatments were used that were as-cleaned, ethanol adsorbed and self-assembled monolayer passivated. With the surface passivated by self-assembled monolayer, there were few voids at the bonding interface. Ductile fracture was observed during tensile testing. The joint had a bond ratio of 97.4% and elongation of 20.4%, which is very close to the base metal and is considered as equal-strength bonding.

*Correspondence address, Fu-Sheng Zhang, Shaanxi Key Laboratory of Friction Welding Technologies, Northwestern Polytechnical University, 127 Youyi West Road, Xi'an, Shaanxi, 710072, P. R. China, Tel.: +86(029)88491426, Fax: +86(029)88491426, E-mail:


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Received: 2016-11-24
Accepted: 2017-02-10
Published Online: 2017-07-05
Published in Print: 2017-07-14

© 2017, Carl Hanser Verlag, München