Effect of interfacial thickness on microstructure, mechanical properties, and modelling of diffusion fused dissimilar Al alloys for process optimization using ANN-GA method

Strength of diffusion bonded AA1100/AA7075 alloys subjected to the lap shear and ram tensile load were performed and Artificial Neural Network (ANN) models was established to inaugurate connection amid input variables. Progress in strength was observed for improved interfacial thickness; however, beyond 6 μm thickness and 375 °C, a decline in strength was noticed. Similar trend was noticed for hardness value at 375 °C, whereas interface hardness is same as that of its hardest base alloy to provide optimum bond strength. In addition, failure nature of developed AA1100/AA7075 alloys is examined using electron microscope and intermetallic at the interface is found using X-ray diffraction pattern. Finally, the optimum values for diffusion bonded joints with their responses are affirmed by experimental results.