Diffusion bonding of Al-alloys is challenging, largely due to the native oxide layer that acts as a diffusion barrier and does not decompose at high temperature. In addition, its susceptibility to deformation at elevated temperatures when under load limits the pressure that can be applied during diffusion bonding. Whilst the use of interlayers has been shown to be successful in achieving a diffusion bonded structure via a transient liquid phase [1], much less success has been reported for an autogenous process.
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