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JOINING OF 6061AL-15 WT.

% SICP COMPOSITE USING TRANSIENT


LIQUID PHASE DIFFUSION BONDING TECHNIQUE WITH MIXED AG-
CU INTERLAYER

Pallab Roy, Tapan Kumar Pal and Joydeep Maity


____________________________________________________________________________

Pallab Roy (presenting author) is Ph.D. Research Scholar, Welding Technology Center,
Department of Metallurgical and Material Engineering, Jadavpur University, Kolkata- 700032,
West Bengal, INDIA. E-Mail: prsec1@gmail.com

Tapan Kumar Pal is Professor & Coordinator, Welding Technology Center, Department of
Metallurgical and Material Engineering, Jadavpur University, Kolkata- 700032, West Bengal,
INDIA. E-mail: tkpal.ju@gmail.com

Joydeep Maity is Associate Professor, Department of Metallurgical and Materials Engineering,


National Institute of Technology, Durgapur-713209, West Bengal, INDIA. E-mail:
joydeep_maity@yahoo.co.in
____________________________________________________________________________

Abstract

In the present study Microstructure and shear strength of transient liquid phase diffusion bonded
6061Al-15 wt.% SiCp extruded composite using a 50 µm thick mixed Ag-Cu powder interlayer
have been investigated. The bonding is carried out in commercial argon environment at 560 °C
and 0.2MPa pressure using 50μm thick mixed Ag-Cu powder interlayer. The bonding
temperature (560°C) was kept above the eutectic temperature (500.6°C) of Al-Cu-Ag ternary
system and below the solidus temperature (582°C) of 6061 matrix alloy. During isothermal
solidification that took 2 h for completion, due to diffusion of Ag and Cu in Al, a ternary liquid
phase evolved. Subsequent cooling formed a ternary phase mixture (α-Al+CuAl2+Ag2Al) upon
eutectic solidification. The kinetics of isothermal solidification was found to be much faster than
that observed for joining pure Al by 50 µm thick Cu foil interlayer (pure monolithic system) as
well as for joining same composite with 50 µm thick pure Cu foil/powder interlayer under similar
temperature and pressure. Presence of brittle eutectic phase mixture (CuAl2 + Ag2Al) led to
poor joint strength at short TLP bonding times. Increased holding time (6 h) erased shrinkage
via solid state diffusion and yielded the highest joint strength (87 MPa) and fair joint efficiency
(83%).

Keywords: 6061-SiCp composite; transient liquid phase diffusion bonding; mixed Cu-Ag
powder interlayer; isothermal solidification; eutectic phase mixture; joint strength.

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1. Introduction at 550°C under 20 MPa pressure in air
Extensive industrial applications of environment. The joint efficiency was poor
aluminium based metal matrix composites due to existence of oxides since the
(AlMMCs) is restricted by the intricacy bonding was not carried out in inert
encountered in joining them by environment or vacuum. Also, application
conventional processes (fusion welding, of high pressure caused a great deal of
solid state diffusion bonding etc.) in spite undesired material deformation. Huang et
of possessing better properties to al. [37] in a current study, ascertained the
monolithic aluminium alloys [1-9]. The viability of joining 2618Al-17 vol.% SiCp
transient liquid phase (TLP) diffusion composite by TLP diffusion bonding using
bonding process which involves four mixed Al-Cu-Ag interlayer. But, neither
stages; namely: (I) dissolution of interlayer detailed mechanism along with kinetics
(II) homogenization of the liquid (III) was studied nor the joint shear strength
isothermal solidification and (IV) was correlated with base material shear
homogenization of bond region at solid strength in terms of joint efficiency.
state [9-26] has been found to be efficient Moreover, their approach was more
for joining AlMMCs. In most of the towards ‘Brazing’ and not ‘TLP diffusion
investigations reported on TLP diffusion bonding’. The use of Al powder mixed with
bonding of AlMMCs, joint shear strength Cu and Ag as an interlayer would instantly
and joint efficiency were investigated form eutectic liquid irrespective of diffusion
keeping low bonding time (maximum of 2 of Cu and Ag in Al based matrix of the
h) without illustrating a relationship with composite. In true TLP diffusion bonding
the fundamental process mechanism [9- process atomic diffusion of mixed Cu and
12, 22-24]. A comprehensive study in view Ag powder interlayer into Al based matrix
of achieving reasonable joint efficiency in of the composite should form transient
correlation with fundamental process liquid phase. Accordingly, in the present
mechanism (particularly the isothermal research work an investigation is carried
solidification stage) was first carried out by out on joining 6061 Al-15 wt.% SiCp
Maity [27,28] and Maity et al. [29-33] for composite by TLP diffusion bonding
joining 6061Al-15 wt.% SiCp composite by process at 560°C, 0.2 MPa, using a 50 µm
TLP diffusion bonding process at 560°C thick mixed Cu-Ag powder interlayer in
under 0.2 MPa pressure using 50 µm thick argon environment. The microstructure
pure copper interlayer (both in foil and development with bonding time has been
powder form). As compared to monolithic meticulously investigated with regard to
pure system improved isothermal process mechanism correlating with joint
solidification kinetics was observed in shear strength and mode of failure.
composite system. With pure Cu interlayer
TLP diffusion bonding of AlMMC involves 2. Experimental procedure
Al-Cu binary system possessing a eutectic 2.1 Material
temperature of 548°C [34]. If mixed Ag-Cu The as-received material was an extruded
is used as an interlayer, the resultant Al- AlMMC rod consisting of 6061Al matrix
Ag-Cu ternary system possesses much alloy (1.0 wt.% Mg, 0.6 wt.% Si, 0.3 wt.%
lower eutectic temperature (500.6°C) [35]. Cu, 0.2 wt.% Cr, 0.6 wt.% Fe and balance
Moreover, the diffusion coefficient of Ag is Al) and 15 wt.% (13 vol.%) silicon carbide
higher than Cu in Al [15, 36]. Thus, at a (SiC) particulate reinforcement.
particular bonding temperature (above
eutectic temperature) higher atomic 2.2 TLP diffusion bonding
mobility of Al-Cu-Ag system as compared The extruded rod was machined to
to Al-Cu system would further improve the produce discs of 15 mm diameter and 10
kinetics of isothermal solidification. mm in height. The faying surfaces of were
Bushby and Scott [23] achieved a bond polished with grades of emery papers
strength of 54 MPa (60% joint efficiency), soaked in kerosene & liquid paraffin (1:1)
in an early study on SiC fibre/Al up to 1000 grit, and finally with 1 μm
composite, using 50 µm thick Ag-29 wt% diamond paste. Then, the surfaces were
Cu foil interlayer, for 30 minutes of holding cleaned in acetone and dried by hot air

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blast. To retain a mixed copper and silver electron microscope (JEOL, JSM-5800)
powder interlayer (1:2.1 by weight) of 50 with energy dispersive X-ray spectroscopy
μm thickness, initially 30 mg of copper (EDS) detector (Oxford INCA EDS
powder and 63 mg of silver powder was System, UK). The grain size measurement
taken and mixed thoroughly by manual of the matrix was carried out following
stirring. The proportion of copper powder ASTM E112 standard [39]. To assess the
and silver powder was chosen on the joint shear strength, bonded samples were
basis of eutectic composition of Al-Cu-Ag machined to 10 mm diameter to eliminate
ternary eutectic system (40 wt.% Al, 19.3 edge effects. These specimens of about
wt.% Cu and 40.7 wt.% Ag) [35]. After 20 mm length and 10 mm diameter and
manual mixing, a few drops of ethanol the as-received composite of similar
were applied to the powder mixture to dimension were loaded in a specially
make a paste. After applying the paste prepared jig (Fig. 1) and the grips were
between the discs, the assembly was pulled in tension in a 100 KN capacity
pressed from both sides and set by an universal testing machine (INSTRON-
adhesive tape. The tape was then locally 8862) at 0.5 mm min–1 cross head speed
dislodged at the joint region and thickness in position control mode to subject the
of the powder interlayer was measured specimen to pure shear stress across the
under optical microscope with graduated bond interface. The fractured surfaces of
eye piece. Thickness of 50 μm was fixed the shear tested specimens were studied
on several trials. Then the weight gain under scanning electron microscope. Thin
was measured in a digital microbalance specimens machined out from around the
(PRECISA-205A-SCS, Switzerland) to fractured surface of the shear tested
determine actual mass of powder specimens were subjected to XRD
interlayer. Considering all specimens, the analysis at slow scan rate (0.5° min−1) in a
mass of mixed powder interlayer (mean ± high resolution X-ray diffractometer (X'
standard deviation) was found to be 87 ± Pert Pro, PANalytical Instruments,
2 mg. Next, the assembly was inserted Netherlands).
inside the diffusion bonding unit
(programmable electric furnace), where
the bonding was carried out at 560°C
under 0.2 MPa pressure in argon
environment. The bonding temperature
was kept above the eutectic temperature
(500.6°C) of Al-Cu-Ag ternary system [35]
and below the solidus temperature
(582°C) of 6061 matrix alloy [38]. The
specimens were heated to the bonding
temperature at a rate of 9°C min–1, held at
that temperature for six different lengths of
bonding time, viz. 20 min, 1 h, 2 h, 3 h, 6 h
and 9 h; and cooled down to 480°C (below
eutectic temperature) at a rate of 5°C min–
1
inside the furnace. Then the specimens
were taken out of the furnace and cooled
in still air to the room temperature.
Fig. 1: Jig for joint strength determination.
2.3 Bonded composite characterization
Bonded cylindrical samples were sliced 3. Results and Discussion
perpendicular to the bonding plane; then 3.1 Microstructure evolution and
polished, etched (using Keller’s reagent) process mechanism
and studied under optical microscope with 3.1.1 As-received Composite
digital photomicrography and image In Fig. 2(a)-(c) the microstructure of as-
analysis facility (ZEISS, Imager.A1m, received extruded AlMMC is shown. SEM
Germany) as well as under a scanning back scattered electron (BSE) image (Fig.

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2(a)) shows randomly dispersed Silicon Segregated SiC particles with very fine
carbide (SiC) particles in 6061Al matrix. phase mixture of bright appearance are
Presence of SiC and an intermetallic identified at bond centerline (Fig. 3). EDS
compound of iron and aluminium (FeAl3) elemental mapping specifies a high
are further confirmed by respective SEM concentration of Cu and Ag around bond
based EDS spectra (Fig. 2(b) and (c)). centerline along with Si and C. At higher
The presence of iron as an impurity in magnification this finely mixed region can
6061 Al alloy in the form of FeAl3 is also be resolved by SEM back scattered
supported by literature [22] and justified electron image (Fig. 5(a)) where presence
with the little solubility of iron in aluminium of two phases, viz. Ag2Al and CuAl2 are
as foreseen in Fe-Al phase diagram [34]. identified in a matrix of aluminium based
α-solid solution as seen in respective EDS
3.1.2 TLP diffusion bonded composites spectra (Fig. 5(b)-(d)), signifying existence
The SEM BSE image at bond centerline of a liquid phase at 560°C even after
and EDS elemental mapping of the holding for 20 min. This liquid is evolved
specimen with 20 min holding are shown through interdiffusion and mixing of Ag
respectively in Fig. 3 and 4. and Cu powders with Al based matrix
since the holding temperature (560°C) is
higher than the eutectic temperature of Al-
Cu-Ag ternary system (500.6°C). The
average width of the region containing
bright eutectic phase mixture (i.e. the
width of prior liquid zone) on 20 min
holding is measured as 69 µm. The first
two stages (melting of interlayer and
widening of liquid) of TLP diffusion
bonding occurs within a few seconds
[14,15]. In the present study, heating from
the eutectic temperature (500.6°C) to the
bonding temperature (560°C) at a rate of
Fig. 3: SEM back scattered electron image 9°Cmin−1 takes about 7 minutes. Thus, the
around bond centerline of the specimen first two stages are completed during
with 20 min holding. heating to the bonding temperature.

Fig. 2: Microstructure of as-received 6061-SiCp composite:


(a) SEM Back scattered electron image (b) EDS spectra of SiC (c) EDS spectra of FeAl3.

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particles are engulfed in the ISZ [29-33].
The region between segregation zone and
base metal solidifies isothermally at
bonding temperature (560°C), forming
‘ISZ’, where the presence of CuAl2 apart
from engulfed SiC and FeAl3, is identified
by SEM back scattered electron image
and EDS spectra (Fig. 6(a)-(d)). CuAl2
phase is found to preferably precipitate on
SiC particle. In bonded composites, the
CuAl2 phase is precipitated out in the ISZ
during cooling from the bonding
temperature as the solubility of Cu in
primary α decreases with decreasing
temperature following the solvus curve
[39], though the as-received unbounded
AlMMC does not contain any CuAl2 phase.
Fig. 7 and 8 shows the SEM micrographs
of the bond region for 1 h holding. The
overall SEM BSE image (Fig. 7) around
bond centerline reveals the presence of
fine bright eutectic mixture of Ag2Al and
CuAl2 in α-matrix, along with segregated
SiC particles. The average width of the
bright eutectic phase mixture region on 1
h holding is measured as 46 µm, lower
than that with 20 min holding (69 µm). The
reduction in the width indicates progress
of isothermal solidification. Besides, high
magnification BSE image of segregation
Fig. 4: EDS elemental mapping around zone separately identifies relatively
bond centerline of the specimen with 20 brighter Ag2Al and less bright CuAl2 (Fig.
min holding. SZ: segregation zone; ISZ: 8(a)). In ISZ (Fig. 8(b)) presence of
Isothermally Solidified Zone. engulfed SiC, CuAl2 precipitate and FeAl3
in α-Al matrix is observed. As a
The liquid widening completes and remarkable feature, several grains are
isothermal solidification starts much observed around the SiC particle (Fig.
before 20 min of holding. Isothermal 8(b)). However, many SiC particles (in the
solidification is not completed on 20 form of cluster/segregation) are not
minutes holding, and some amount of present at the triple point junction of the
liquid is left out around bond centerline grains. This signifies that the SiC particle
adjacent to isothermally solidified zone is not pushed and subsequently entrapped
(ISZ). This residual liquid, undergoes by the converging solidification fronts.
ternary eutectic reaction [35] during During engulfment, solidification front
cooling from bonding temperature to room splits to generate many grains around a
temperature,: Liquid → α + Ag2Al + CuAl2. particle. Solidification fronts recombine
At 560°C, this liquid phase (eutectic away from the particle. In literature similar
mixture of α, Ag2Al and CuAl2 at room phenomenon is reported [31,40].
temperature) together with SiC particles
form the ‘segregation zone’. During For 2 hours of holding, bond centerline is
isothermal solidification, relatively smaller devoid of any eutectic mixture (Fig. 9(a)),
SiC particles are pushed by the moving indicating nonexistence of any liquid
solidification front and segregate around phase at 560°C that would have
the bond centerline; while coarser transformed to eutectic mixture during
cooling.

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Fig. 5: SEM analysis of SZ at high magnification in the specimen with 20 min holding: (a)
SEM BSE image; and EDS spectra of (b) CuAl2, (c) Ag2Al, and (d) α-solid solution.

Fig. 6: SEM analysis of ISZ in the specimen with 20 min holding: (a) SEM back scattered
electron image; and EDS spectra of (b) SiC, (c) CuAl2, and (d) FeAl3.

This confirms the completion of isothermal matrix interfacial region of high dislocation
solidification with 2 hours of holding at density unlike monolithic aluminium [38,
560°C for joining 6061Al-15 wt.% SiCp 41-43]. While joining 6061 Al-15 wt. % SiC
composite using mixed Cu-Ag powder by TLP diffusion bonding technique using
interlayer. According to Natsume et al. 50 μm thick Cu powder interlayer under
[15] and further analysis by Maity [27], for 0.2 MPa pressure at 560°C, Maity et al.
joining pure aluminium by 50 μm Cu [31] experienced 3 hours holding time for
interlayer at 570°C, isothermal isothermal solidification completion.
solidification takes about 9 hours 46 Hence, kinetics of TLP diffusion bonding is
minutes for completion. This is much further accelerated at 560°C with the use
longer duration of isothermal solidification of mixed Cu-Ag powder interlayer instead
proportionate to much slower diffusion of pure Cu powder interlayer. On
coefficient of Cu in pure aluminium, completion of isothermal solidification the
attributed to short-circuit diffusion in entire bond region is basically the ISZ
composite through defect-rich particle-

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containing engulfed SiC, CuAl2 precipitate diminished through diffusion later on (6 h
and FeAl3 in α-Al matrix (Fig. (9(a)). holding), corroborating completion of
homogenization of bond region with 6 h
holding. Now, the diffusivity (D) of Cu in Al
and that of Ag in Al at the bonding
temperature (T = 833 K) can be calculated
based on the values of the frequency
factor (D0) and the activation energy (Q)
found from standard literature [15,36]
using the relationship: D = D0 e–Q/RT
(where, R = 8.314 J.mol–1.K–1, the molar
gas constant). D0 = 1.50 × 10–5 and 9 ×
10–4 m2 s–1; and Q = 1.26 × 105 and 1.10 ×
105 J mol–1 for diffusion of Cu in Al and
that of Ag in Al, respectively. Thus, it is
Fig. 7: SEM back scattered electron image found that at 560°C (T = 833 K), the
around bond centerline of the specimen diffusivity of Ag (1.14 × 10–10 m2 s–1) is
with 1 h holding. much higher than that of Cu (1.89 × 10–13
m2 s–1). Presence of Ag in the form of
Analogous microstructural features are Ag2Al precipitate is not found in the ISZ,
observed for still higher bonding time viz. though CuAl2 precipitate is readily found,
3 h, 6 h and 9 h (Fig. 9(b)-(d)) where attributed to the higher solubility of Ag in
entire bond region is isothermally Al than Cu in Al as observed in Ag-Al and
solidified. Shrinkage porosity appears Cu-Al phase diagrams [34]. So, Ag mainly
around bond centerline on completion of remains in the primary α-solid solution
isothermal solidification (2 h holding) (Fig. (aluminium based terminal solid solution)
9(a)) and persists for 3 h holding (Fig. in the ISZ; whereas in the segregation
9(b)). Prolonged holding up to 6 h zone it is present as eutectic Ag2Al. The
eliminates these porosities (Fig. 9(c)) results of XRD study (Fig. 11) agree with
through solid state atomic diffusion under the peaks of Al, SiC and FeAl3 in as-
pressure (0.2 MPa). received composite. During isothermal
solidification (20 min and 1 h holding),
peaks of Al, SiC, Ag2Al, CuAl2 and FeAl3
are observed in bonded composites. On
completion of isothermal solidification (2 h
holding and onwards), peaks of all phases
except Ag2Al are obtained due to absence
of eutectic phases where bond region is
entirely ISZ and Ag mainly goes to solid
Fig. 8: SEM backscattered electron image solution.
of the bond region at higher magnification
in the specimen with 1 h holding: (a) 3.2 Bond strength and fractured
Segregation zone; (b) Isothermally surface
Solidified Zone. In Fig. 12, shear strength of the joint for
various bonding time is graphically
Another noteworthy feature observed is presented. The as-received composite
the existence of SiC particle segregation possesses shear strength of 105±2 MPa
(Fig. 9(a)-(d)) even on completion of [27]. At lesser bonding time (20 min and 1
isothermal solidification. In Fig. 10(a)-(b) h) the bond strength is low and with
the selected EDS line scans representing increasing holding time the bond strength
concentration variation of two main increases up to 6 h holding and then
diffusing species Ag and Cu across the decreases. The highest joint strength
bond interface are shown. The (87±3 MPa) of the bonded composite is
concentration gradient of Ag and Cu achieved with 6 h holding, which is 83% of
existing initially (20 min holding) is the shear strength (105 MPa [27]) of the

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as-received composite (representing 83% particles are the failure initiation sites. On
joint efficiency). The fractured surface of completion of isothermal solidification (2 h
shear tested as-received composite holding), joint strength is further improved
exhibits dimples and tear ridges (Fig. due to elimination of eutectic phase
13(a) and (b)), feature of distinctive ductile mixture from joint region. Here, fractured
fracture of Al/SiCp composite [44]. In Fig. surface mainly contains SiC particle
14(a)-(f) back-scattered electron images segregation, which is primarily responsible
of the fractured surfaces of bonded for failure (Fig. 14(c)). Also, solidification
composites are shown. For specimen with shrinkage porosity is observed on
20 min holding (Fig. 14(a)) flat brittle fractured surface (Fig. 14(c)) in
fractured surface is observed. accordance with that identified in SEM
Considerable existence of bright eutectic metallography at the joint region (Fig.
phase mixture (CuAl2+Ag2Al) with a few 9(a)). Therefore, solidification shrinkage
segregated SiC particles is visible. This porosities are the secondary sites for
shows that the brittle intermetallic eutectic failure. Fractured surface for 3 h holding
particles (CuAl2+Ag2Al) are accountable (Fig. 14(d)) exhibits features similar to that
for failure with poor joint strength. The for 2 h holding, but the proportion of
failure occurs primarily through shrinkage porosity appears to be reduced
decohesion at eutectic particle-matrix (Fig. 14(d) and 9(b)). Further holding at
interface in the segregation zone. In case solid state up to 6 h eliminates
of the specimen with 1 h holding, fractured solidification shrinkage porosity through
surface (Fig. 14(b)) reveals the presence solid state diffusion as observed in
of a large SiC cluster along with bright fractured surface (Fig. 14(e)) and SEM
eutectic phase mixture (CuAl2+Ag2Al). As metallography at the joint region (Fig.
isothermal solidification advances, 9(c)). Accordingly, highest joint strength
proportion of eutectic phase mixture is (87 MPa) and joint efficiency (83%) are
reduced (since amount of liquid phase is achieved for 6 h bonding time. Here,
reduced) and proportion of segregated segregated SiC particles are the main
SiC particles is increased (due to more failure initiation sites ((Fig. 14(e)).
particle pushing by solidification front), Fractured surface for 9 h holding (Fig.
resulting in improved joint strength. In this 14(f)) appears similar to that of 6 h
case, both SiC cluster and brittle eutectic holding.

Fig. 9: SEM back scattered electron images of the bond region for higher bonding time:
(a) 2 h; (b) 3 h; (c) 6 h; and (d) 9 h.

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However, the joint strength is reduced on in the present investigation appears to be
9 h holding as compared to 6 h holding. a reasonable one. However, the presence
This is attributed to grain coarsening of of particle segregation even after
the isothermally solidified joint region on completion of isothermal solidification is
prolong holding at solid state. responsible for not obtaining still higher
(above 90%) joint efficiency.

Fig. 10: Selected EDS line scans


representing the concentration variation of
Ag and Cu across the bond centerline:
(a) 20 min; (b) 6 h.

Fig. 12: Variation of mean shear strength


of the bond region with bonding time.

4. Conclusion
(i) TLP bonding of extruded 6061 Al-15
wt.% SiCp composite (560°C, 0.2 MPa)
using 50 µm thick mixed Ag-Cu powder
interlayer formed a ternary phase mixture
(α-Al+CuAl2+Ag2Al) upon eutectic
solidification that was completed in 2 h.
(ii) Compared to pure Cu interlayer, the
mixed Ag-Cu powder interlayer
accelerated the TLP bonding though
during isothermal solidification SiC
segregated.
(iii) Because of the brittle eutectic phase
mixture (CuAl2+Ag2Al) short TLP bonding
Fig. 11: Results of X-ray diffraction times led to low joint strength. With 2 h
analysis. long isothermal solidification, the brittle
mixture vanished leading to improved joint
The grain boundaries are clearly strength though peak strength was not
delineated in optical metallography. The achieved due to solidification shrinkage.
grain sizes of the aluminium based matrix (iv) Through solid state diffusion, longer (6
at bond region measured (in terms of h) hold eliminated shrinkage porosity and
average grain diameter) from optical led to highest strength (87 MPa) with 83%
micrographs (Fig. 15(a) and (b)) of the joint efficiency. The failure occurred via
specimens with 6 h and 9 h holdings are decohesion at SiC cluster-matrix interface.
73±7 µm and 148±9 µm, respectively. This (v) Due to significant grain coarsening,
indicates substantial grain coarsening prolong hold (up to 9 h) reduced the joint
effect reducing the joint strength on strength.
prolong holding (9 h) at solid state.
Compared to other investigations, the
maximum joint efficiency achieved (83%)

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Fig. 13: SEM micrographs of the fractured surface of as-received composite:
(a) Secondary electron image; (b) Back-scattered electron image.

Fig. 14: SEM back-scattered electron images of the fractured surfaces of bonded
composites: (a) 20 min; (b) 1 h; (c) 2 h; (d) 3 h; (e) 6 h; and (f) 9 h.

Fig. 15: Matrix grain size for holding times of (a) 6 h and (b) 9 h.

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