Understanding Oxide–Metal Interactions During Hot Isostatic Pressing to Diffusion Bond Aluminum Alloy 6061 Plates

Schulthess, Jason L.; Pido, Shayndel; Noei, Nima; Gharavi, Paria; Sohn, Yongho

doi:10.1007/s11661-025-08029-3

Understanding Oxide–Metal Interactions During Hot Isostatic Pressing to Diffusion Bond Aluminum Alloy 6061 Plates

Journal Article · Mon Nov 03 00:00:00 EST 2025 · Metallurgical and Materials Transactions. A, Physical Metallurgy and Materials Science

DOI:https://doi.org/10.1007/s11661-025-08029-3· OSTI ID:3017253

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Idaho National Laboratory (INL), Idaho Falls, ID (United States)
Univ. of Central Florida, Orlando, FL (United States)

The interaction between Mg, Si, and Al₂O₃ during hot isostatic pressing diffusion bonding of aluminum alloy 6061 (AA6061) plates was investigated through thermodynamic calculations and experimental microstructural characterization. Thermodynamic calculations as functions of temperature, pressure, and composition revealed that the interaction among Mg, Si, and Al₂O₃ yields Mg₂Si and either MgO + Al or MgAl₂O₄ + Al, facilitating the reduction of Al₂O₃ and allowing Al/Al metallic bonds to form. Total pressure variation had a negligible influence on the oxygen partial pressure, and consequently, the reaction product formation. Oxygen partial pressure variation as a function of temperature and initial amount of Al₂O₃ determined the formation of either MgO or MgAl₂O₄. Experimental Hot Isostatic Pressure (HIP) bonding at 723 K and 833 K under a constant pressure of 1017 atm documented the cooling rate-dependent formation of β–Mg₂Si precipitates. High-resolution transmission electron microscopy imaging and selected area electron diffraction patterns verified the formation of β–Mg₂Si and MgO at the interface but did not detect MgAl₂O₄. In conclusion, findings from this study clarify the role of thermochemical interactions in oxide disruption and bonding mechanisms during HIP diffusion bonding of AA6061 and provide guidance for optimizing joining processes for monolithic nuclear fuel assemblies.

View Accepted Manuscript (DOE)

Research Organization:: Idaho National Laboratory (INL), Idaho Falls, ID (United States)

Sponsoring Organization:: USDOE National Nuclear Security Administration (NNSA); USDOE Office of Nuclear Energy (NE)

Grant/Contract Number:: AC07-05ID14517

OSTI ID:: 3017253

Report Number(s):: INL/JOU--25-84489

Journal Information:: Metallurgical and Materials Transactions. A, Physical Metallurgy and Materials Science, Journal Name: Metallurgical and Materials Transactions. A, Physical Metallurgy and Materials Science Journal Issue: 1 Vol. 57; ISSN 1543-1940; ISSN 1073-5623

Publisher:: SpringerCopyright Statement

Country of Publication:: United States

Language:: English

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