EVALUATIONS OF INTERFACE BOND STRENGTH BETWEEN THERMAL SPRAYED COATINGS AND SUBSTRATS

A novel test method of measuring the interface bond strength between a thermal sprayed coating and substrate is put forward first in this paper. The test method is simple and reliable, and exists no any inherent shortcoming and controversy. The interface bond strength obtained by the test method is completely the inherent property of the interface and depends only on coating material properties, spray conditions, and technique of depositing the coating. By extensive tests, it is shown that the test tesults are very tepeatable and reliable. Furthermore, from this test, the critical coating thickness under which the coating spall can not emerge is also obtained.

Effects of Surface Roughness on Interface Bonding Performance for 316H Stainless Steel in Hot-Compression Bonding

The metallurgical bonding quality of bonding joints is affected by the substrate surface state in hot-compression bonding(HCB),and the surface roughness is a core indicator of the surface state.However,the effects of surface roughness on interface bonding performance(IBP)in the HCB process are unclear for substrates with refractory oxide scales.This study presents the effects of surface roughness on IBP for 316H stainless steel joints fabricated by HCB.A set of HCB parameters for interface bonding critical state of 316H stainless steel joints was determined.The HCB experiments were carried out under parameters of interface bonding critical state to amplify the effect of surface roughness.The interface morphologies,element distribution,and tensile properties were used to characterize the IBP.As a result,the formation mechanisms of the interface pits were revealed and the variation trend of pit number with the roughness was summarized.Finally,the mapping relation between surface roughness and IBP was established.The results show that the degree of rotational dynamic recrystallization becomes weaker with the decrease in the surface roughness and the interface bonding mechanism is completely transformed into discontinuous dynamic recrystallization when the roughness is lower than 0.020μm Sa.The number of interfacial pits decreases as the roughness decreases owing to the weakening of oxide scale aggregation and abrasive inclusion mechanism.The elongation of the tensile specimen cannot increase significantly while the roughness is lower than 0.698μm Sa.

Bonding interface characteristic and shear strength of diffusion bonded Ti-17 titanium alloy

The bonding interface characteristic and shear strength of diffusion bonded Ti-17 titanium alloy at different bonding time were investigated. The results show that the average size of voids decreases while the amount of voids decreases after increasing to the maximum value with the increasing bonding time. The irregular void with a scraggly edge tends to an ellipse void with smooth surface and then changes to a tiny void with round shape. The grains across bonding interface occur at bonding time of 60 min. The shear strength of bond increases with increasing bonding time, and the highest shear strength of bond is 887.4 MPa at 60 min. The contribution of plastic deformation on the void closure and the increase of shear strength is significant even though the action time of plastic deformation is short.

Effect of grain size of primary α phase on bonding interface characteristic and mechanical property of press bonded Ti-6Al-4V alloy

The effect of grain size of primary α phase on the bonding interface characteristic and shear strength of bond was investigated in the press bonding of Ti-6Al-4V alloy. The quantitative results show that the average size of voids increases from 0.8 to 2.6 μm and the bonding ratio decreases from 90.9% to 77.8% with an increase in grain size of primary α phase from 8.2 to 16.4 μm. The shape of voids changes from the tiny round to the irregular strip. The highest shear strength of bond can be obtained in the Ti-6Al-4V alloy with a grain size of 8.2 μm. This is contributed to the higher ability of plastic flow and more short-paths for diffusion in the alloy with smaller grain size of primary α phase, which promote the void closure process and the formation of α/β grains across bonding interface.

Microstructure and properties at bonding interface of AA4045/AA3003 aluminum alloy cladding billet prepared by semi-continuous casting

AA4045/AA3003 cladding billet was prepared by direct chill semi-continuous casting process. The macrostructures, microstructures, temperature distribution, compositions distribution and the mechanical properties at the bonding interface were investigated in detail. The results show that the cladding billet with few defects could be obtained by semi-continuous casting process. At the interface, diffusion layer of about 10μm on average formed between the two alloys due to the diffusion of alloy elements in the temperature range from 596 to 632 °C. From the side of AA4045 to the side of AA3003, the Si content has a trend to decrease, while the Mn content has a trend to increase gradually. Tensile strength of the cladding billet reaches 103.7 MPa, the fractured position is located on the AA3003 side, and the shearing strength is 91.1 MPa, revealing that the two alloys were combined metallurgically by mutual diffusion of alloy elements.

Evolution of bonding interface in solid-liquid cast-rolling bonding of Cu/Al clad strip

Cu/Al clad strips are prepared using solid?liquid cast-rolling bonding(SLCRB)technique with a d160mm×150mm twin-roll experimental caster.The extent of interfacial reactions,composition of the reaction products,and their micro-morphology evolution in the SLCRB process are investigated with scanning electron microscope(SEM),energy dispersive spectrometer(EDS),and X-ray diffraction(XRD).In the casting pool,initial aluminized coating is first generated on the copper strip surface,with the diffusion layer mainly consisting ofα(Al)+CuAl2and growing at high temperatures,with the maximum thickness of10μm.After sequent rolling below the kiss point,the diffusion layer is broken by severe elongation,which leads to an additional crack bond process with a fresh interface of virgin base metal.The average thickness is reduced from10to5μm.The reaction products,CuAl2,CuAl,and Cu9Al4,are dispersed along the rolling direction.Peeling and bending test results indicate that the fracture occurs in the aluminum substrate,and the morphology is a dimple pattern.No crack or separation is found at the bonding interface after90°-180°bending.The presented method provides an economical way to fabricate Cu/Al clad strip directly.

Mode-I fracture and durability of FRP-concrete bonded interfaces

In this study, a work-of-fracture method using a three-point bend beam （3PBB） specimen, which is commonly used to determine the fracture energy of concrete, was adapted to evaluate the mode-I fracture and durability of fiber-reinforced polymer （FRP） composite-concrete bonded interfaces. Interface fracture properties were evaluated with established data reduction procedures. The proposed test method is primarily for use in evaluating the effects of freeze-thaw （F-T） and wet-dry （W-D） cycles that are the accelerated aging protocols on the mode-I fracture of carbon FRP-concrete bonded interfaces. The results of the mode-I fracture tests of F-T and W-D cycle-conditioned specimens show that both the critical load and fracture energy decrease as the number of cycles increases, and their degradation pattern has a nearly linear relationship with the number of cycles. However, compared with the effect of the F-T cycles, the critical load and fracture energy degrade at a slower rate with W-D cycles, which suggests that F-T cyclic conditioning causes more deterioration of carbon fiber-reinforced polymer （CFRP）-concrete bonded interface. After 50 and 100 conditioning cycles, scaling of concrete was observed in all the specimens subjected to F-T cycles, but not in those subjected to W-D cycles. The examination of interface fracture surfaces along the bonded interfaces with varying numbers of F-T and W-D conditioning cycles shows that （1） cohesive failure of CFRP composites is not observed in all fractured surfaces; （2） for the control specimens that have not been exposed to any conditioning cycles, the majority of interface failure is a result of cohesive fracture of concrete （peeling of concrete from the concrete substrate）, which means that the cracks mostly propagate within the concrete; and （3） as the number of F-T or W-D conditioning cycles increases, adhesive failure along the interface begins to emerge and gradually increases. It is thus concluded that the fracture properties （i.e., the critical load and fracture energy） of the bonded interface are controlled primarily by the concrete cohesive fracture before conditioning and by the adhesive interface fracture after many cycles of F-T or W-D conditioning. As demonstrated in this study, a test method using 3PBB specimens combined with a fictitious crack model and experimental conditioning protocols for durability can be used as an effective qualification method to test new hybrid material interface bonds and to evaluate durability-related effects on the interfaces.

Bonding interface zone of Mg-Gd-Y/Mg-Zn-Gd laminated composite fabricated by equal channel angular extrusion

In order to improve the mechanical properties and corrosion resistance of Mg alloys,the equal channel angular extrusion (ECAE)was employed to fabricate the Mg-5Gd-5Y/Mg-2Zn-1Gd(GW55/ZG21)laminated composites.After fabrication and annealing treatment,the microstructural evolution,phase constitution,microhardness,and bonding strength were investigated on the bonding interface zone of GW55/ZG21 laminated composites.The bonding interface zone of GW55/ZG21 laminated composites comprises a lot of Mg3(Y,Gd)2Zn3 particles along the bonding interface,some rod Mg24(Y,Gd)5 phases on GW55 side,and a precipitation free zone(PFZ)on ZG21 side.After annealing treatment,Mg3(Y,Gd)2Zn3 particles along the bonding interface increase, rod Mg24(Y,Gd)5 phases on GW55 side decrease,and PFZ is broadened.Meanwhile,the hardness on the bonding interface zone decreases and the bonding strength increases from 126 MPa to 162 MPa.

Ratio of Fe-Al compound at interface of steel-backed Al-graphite semi-solid bonding plate

The ratio of Fe-Al compound at the bonding interface of solid steel plate to Al-7graphite slurry was used to characterize the interracial structure of steel-Al-7graphite semi-solid bonding plate quantitatively. The relationship between the ratio of Fe-Al compound at interface and bonding parameters （such as preheat temperature of steel plate, solid fraction of Al-7graphite slurry and rolling speed） was established by artificial neural networks perfectly. The results show that when the bonding parameters are 516 ℃ for preheat temperature of steel plate, 32.5% for solid fraction of Al-7graphite slurry and 12 mm/s for rolling speed, the reasonable ratio of Fe-Al compound corresponding to the largest interfacial shear strength of bonding plate is obtained to be 70.1%. This reasonable ratio of Fe-Al compound is a quantitative criterion of interracial embrittlement, namely, when the ratio of Fe-Al compound at interface is larger than 70.1%, interfacial embrittlement will occur.

MICROSTRUCTURE CHARACTERISTICS AT THE BOND INTERFACE

Lift-off and section characteristics at the interface of thermosonic bond are observed by using scanning electron microscope （KYKY2800） with EDS-test. Results show that the peeling underdeveloped bonds simulate atorns （or doughnut） with an unbonded central region and ridged peripheral region is bonded hardly, Inside roundness at flip chip bonding center are discovered. Bond strength is located between the severely ridged periphery and the non-adhering central area of the bond. For constant force and time, the ridged area of the bond pattern increases when more power is applied. For constant force and power, the ridged location of the bonded region moves closer to the bond center with time. Results of EDS-tests at Au-Al and Au-Ag interfaces show that Kirkendall diffusibility at Au-Ag interface occur and the diffusing speed of Au-atomic is faster than that of Ag, and that intermetallic compounds at Au-Al interface is generated possibly. And these would be helpful for further research about thermosonic bonding.

Bonding interface morphology of keyholeless friction stir spot welded joint of AZ31B Mg alloy and DP600 galvanized steel

Because the bonding interface of dissimilar metal joint between AZ31 B Mg alloy and DP600 galvanized steel by keyholeless friction stir spot welding(KFSSW)is permanent bonding,the interface morphology cannot be directly observed.If the joint is separated by external force,the original features of bonding interface of joint will be destroyed,which has influence on the accuracy for observation and analysis of the result.In this paper,the coordinates of the key point at the interface of every cross-section at intervals of 0.2 mm were measured and connected into an outline.The outline of all interfaces makes up the three-dimensional morphologies of bonding interface between AZ31 B Mg alloy and DP600 steel by KFSSW,which was constructed by Solidworks software to restore the real mechanical bonding state of joint.Combined with the microhardness analysis of cross-section and results of in-situ tensile test,the unique bonding state and morphology of Mg and steel in the welded joint were confirmed.

An investigation on bonding interface microstructure of ceramic coating prepared on AZ91D by evaporated pattern casting technique

PbO-ZnO-Na20 ceramic coating was fabricated on the AZ91D Mg-alloy substrate surface by using of evaporated pattern casting （EPC） process. The ceramic coating was characterized through scanning electron microscopy （SEM） observation, energy dispersive X-ray spectrometer （EDS） and so on. The research was emphasized on the formation process of ceramic coating and the interface bonding conditions between ceramic coating and the substrate. Results show that the glass powder （PbO-ZnO-NazO） melts when contacts with the high temperature liquid metal, and solidifies on the surface of the substrate with the decrease of temperature. Therefore, the ceramic coating was successfully prepared with the formation of the bonding interface with the substrate, Beside the influence of coating layer thickness, the vacuum level was also investigated. Further analysis indicates that oxide inclusions and decomposition products of foam pattern had a significant effect on the bonding interface： To obtain a good bonding interface between the ceramic coating and the substrate, the metal liquid oxidation and inclusions must be decreased and the decomposition products of foam pattern should be exhausted from the EPC coating completely.

Chemical bonding of perovskite LaFeO_(3) with Li_(1.2)Mn_(0.6)Ni_(0.2)O_(2) to moderate anion redox for achieving high cycling stability

Oxygen anion redox reaction provides a high theoretical capacity for Li-rich manganese-based cathodes.However,irreversible surface oxygen release often results in further oxygen loss and exacerbates the decomposition of the electrolyte,which could reduce the capacity contribution from the anionic redox and produce more acidic substances to corrode the surface of the material.In this paper,the surface oxygen release is suppressed by moderating oxygen anion redox activity via constructing chemical bonds between M(M=Fe and La)in LaFeO_(3)and surface oxygen anions of Li_(1.2)Mn_(0.6)Ni_(0.2)O_(2).The constructed interface layer stabilizes the surface lattice oxygen and retards the electrolyte from being attacked by the nucleophilic oxygen generated in the process of oxygen release,as evidenced by Differential Electrochemical Mass Spectrometry(DEMS)and X-ray Photoelectron Spectroscopy(XPS)detections.Moreover,in the charge and discharge process,the formed FeF_(3),located at the cathode electrolyte interfacial layer,is conducive to the stability of the cathode surface.The modified Li_(1.2)Mn_(0.6)Ni_(0.2)O_(2)electrode with 3 wt%LaFeO_(13)exhibits a high specific capacity of 189.5 mA h g-at 1C(200 mA g^(-1))after 150 cycles with capacity retentions of 96.6%,and 112.6 mA h g^(-1)(84.7%)at 5C after 200 cycles higher than the pristine sample.This study provides a rational design chemical bonding method to suppress the oxygen release from the cathode surface and enhance cyclic stability.

Influence of Mass Ratio of Resin and Stabilizer on Mechanical Properties of Mo Fiber-reinforced Granite Polymer Composite

Because inferior mechanical strength of granite polymer composite(GPC)has become the main drawback limiting its application and popularization,Mo fibers were added into(GPC)to improve its mechanical strength.Mechanical properties of matrix materials with different mass ratio of resin and stabilizer(MRRS)were investigated systematically.The influences of MRRS on interface bonding strength of Mo fiber-matrix,wettability and mechanical strength of GPC were discussed,respectively,and the theoretical calculation result of MRRS k was obtained,with the optimal value of k=4.When k=4,tensile strength,tensile strain and fracture stress of the cured resin achieve the maximum values.But for k=7,the corresponding values reach the minimum.With the increase of MRRS k,surface free energy of the cured resin first increases and then decreases,while contact angles between Mo sample and matrix have displayed the opposite trend.Wettability of resin to Mo fiber is the best at k=4.Pulling load of Mo fiber and interface bonding strength appear the maximum at k=4,followed by k=5,k=3 the third,and k=7 the minimum.When k=4,mechanical properties of Mo fiber-reinforced GPC are optimal,which is consistent with the result of theoretical calculation.This study is of great significance to get better component formulas of Mo fiber reinforced GPC and to improve its application in machine tools.

Improvement of the matrix and the interface quality of a Cu/Al composite by the MARB process

The matrix accumulative roll bonding technology （MARB） can improve the matrix performance of metal composite and strengthen the bonding quality of the interface./n this research, for the fwst time, the technology of MARB was proposed. A sound Cu/AI bonding composite was obtained using the MARB process and the bonding characteristic of the interface was studied using scanning electricity microscope （SEM） and energy-dispersive spectroscopy （EDS）. The result indicated that accumulation cycles and diffusion annealing temperature were the most important factors for fabricating a Cu/AI composite material. The substrate aluminum was strengthened by MARB, and a high quality Cu/AI composite with sound interface was obtained as well.

Bonding mechanism of X10CrNi18-8 with Ni/Al_2O_3 composite ceramic by pressureless infiltration

Abstract： An alloy steel/alumina composite was successfully fabricated by pressureless infiltration of X10CrNil8-8 steel melt on 30% （mass fraction） Ni-containing alumina based composite ceramic （Ni/Al2O3） at 1 600 ℃. The infiltration quality and interfacial bonding behavior were investigated by SEM, EDS, XRD and tensile tests. The results show that there is an obvious interfacial reaction layer between the alloying steel and the Ni/Al2O3 composite ceramic. The interfacial reactive products are （FexAly）3O4 intermetallic phase and （AlxCry）2O3 solid solution. The interracial bonding strength is as high as about 67.5 MPa. The bonding mechanism of X10CrNi 18-8 steel with the composite ceramic is that Ni inside the ceramic bodies dissolves into the alloy melt and transforms into liquid channels, consequently inducing the steel melt infiltrating and filling in the pores and the liquid channels. Moreover, the metallurgical bonding and interfacial reactive bonding also play a key role on the stability of the bonding interface.

Comparisons of interface microstructure and mechanical behavior between Ti/Al and Ti-6Al-4V/Al bimetallic composites

The microstructure, interface thickness, element distribution and interfacial mechanical behavior of Ti-6Al-4V/Al couples prepared by an insert moulding method were investigated in depth in this paper. Moreover, Ti/Al bonding was also given as a comparison for understanding the interface bonding mechanism. It is shown that there is much thinner compact sub-layer for the interface of the Ti-6Al-4V/Al joint, whose morphology is obviously different from that of the Ti/Al joint. The Ti-6Al-4V/Al interface has been proven to contain a slight content of vanadium. Moreover, both the shear strength and the interface reaction rate of Ti-6Al-4V/Al compound materials are lower than those of the Ti/Al ones.

Study on Interfacial Bonding State of Ag-Cu in Cold Pressure Welding

The interfacial bonding of Ag-Cu (they are limited soluble) formed by the technology of cold pressure welding was discussed from the point of metallurgic view in this paper. Meanwhile, tensile test and microscopic test were adopted for studying the state of interfacial bonding, suggesting that the joint of Ag-Cu has not only strong welding joint but also atomic diffusion on the interface. For Ag-Cu, the interaction of dislocation caused by plastic deformation will cause the strain and the vibration of microconstructer defects, accompanied by emitting energy. The energy increases the atomic action and the amplitude of atomic vibration, and the result is that the atom can diffuse to several lattice parameters deep from interface to inner metals. Therefore, under the condition of chemical potential gradient, the special technique, cold pressure welding rather than basic requirements of diffusion should be taken into account. During the cold pressure welding, plastic deformation plays an important role for it causes the metals′ displacement, crystal defects, further activates the surface atoms. Finally, the fracture of atomic bonding leads to the atomic exchange and diffusion between the new metals′ surfaces.In other words the metals Ag,Cu can achieve solidate bonding by cold pressure welding accompanied by the atomic diffusion. Moreover, theoretical analysis and calculation on the basis of thermodynamics, crystallogy, so- lid physics,etc, have been applied to calculate the amount of atomic diffusion, which has further proved the testing results that joint Ag-Cu has strong bonding strength through the mechanism of atomic diffusion.

Study on Shear Strength Characteristics of Basalt-Concrete Bonding Interface Based on in-situ Direct Shear Test

In rock engineering,the shear strength of the basalt-concrete bonding interface is a key factor affecting the shear performance of hydroelectric dam foundations,embedded rock piles and rock bolts.In this study,30 sets of in-situ direct shear tests were conducted on the basalt-concrete bond interface in the Baihetan dam area to investigate the shear strength characteristics of the basalt-concrete bonding interface.The bonding interface contains two states,i.e.,the bonding interface is not sheared,termed as se(symbolic meaning see Table 1);the bonding interface is sheared with rupture surface,termed as si.The effects of lithology,Joints structure,rock type grade and concrete compressive strength on the shear strength of the concrete-basalt contact surface were investigated.The test results show that the shear strength of the bonding interface(s_(e)&s_(i))of columnar jointed basalt with concrete is greater than that of the bonding interface(s_(e)&s_(i))of non-columnar jointed one with the same rock type grade.When the rock type grade isⅢ_(2),fcol is 1.22 times higher than fncol and ccol is 1.13 times greater than cncol.The shear strength parameters of the basalt-concrete bonding interface differ significantly for different lithologies.The cohesion of the bonding interface(s_(i))of cryptocrystalline basalt with concrete is 2.05 times higher than that of the bonding interface(s_(i))of breccia lava with concrete under the same rock type grade condition.Rock type grade has a large influence on the shear strength of the non-columnar jointed basalt-concrete bonding interface(s_(e)&s_(i)).cnol increases by 33%when the grade of rock type rises fromⅢ_(1)toⅡ_(1).the rock type grade has a greater effect on bonding interface(s_(i))cohesion than the coefficient of friction.When the rock type grade is reduced fromⅢ_(2)toⅢ_(1),f_(ncol)′increases by 2%and c_(ncol)′improves by 44%.The shear strength of the non-columnar jointed basalt-concrete bonding interface(s_(e)&s_(i))increases with the increase of the compressive strength of concrete.When concrete compressive strength rises from 22.2 to 27.6 MPa,the cohesion increases by 94%.

Lattice structures and electronic properties of WZ-CuInS2/WZ-CdS interface from first-principles calculations

Using the first-principles plane-wave calculations within density functional theory, the perfect bi-layer and monolayer terminated WZ-CIS （100）/WZ-CdS （100） interfaces are investigated. After relaxation the atomic positions and the bond lengths change slightly on the two interfaces. The WZ-CIS/WZ-CdS interfaces can exist stably, when the interface bonding energies are -0.481 J/m2 （bi-layer terminated interface） and -0.677 J/m2 （monolayer terminated interface）. Via analysis of the density of states, difference charge density and Bader charges, no interface state is found near the Fermi level. The stronger adhesion of the monolayer terminated interface is attributed to more electron transformations and orbital hybridizations, promoting stable interfacial bonds between atoms than those on a bi-layer terminated interface.