Microcantilever bend testing and finite element simulations of HIP-ed interface-free bulk Al and Al-Al HIP bonded interfaces

We report on the strength of Al-Al interfaces and the effects of chemical segregation and interfacial void formation on bond strength using microcantilever bend testing. Interfaces are synthesised via hot isostatic pressing. Microcantilevers of several nominal dimensions were fabricated via focused ion beam and deformed in a nanoindenter. We find increased cantilever strength as a function of decreasing sample size, with a linear dependence of the yield strength on the inverse square root of the length scale characteristic to the cantilever cross-section. The presence of pores and chemical segregation decreases the yield strength of the material by 17% and the accommodated strain energy by 10-15% for strain values in the 6-12% range.