Date of Award

January 2012

Document Type


Degree Name

Master of Science (MS)


Mechanical Engineering

First Advisor

Matthew Cavalli


The goal of this project is a statistical study of diffusion bonding of commercially pure Ni with a brass interlayer. Four factors were investigated; time, temperature, surface finish, and foil thickness. A Box-Behnken design was selected to analyze the system for composition and strength of the bonded joints. Bonding of the materials was successful. The composition results proved to provide a good model with a fairly low standard error that can accurately predict the composition of the system across the diffusion bond area. The strength model provided two significant terms, and had a very high standard error. This meant that the model was not very good at predicting the strength of the joint because of manufacturing variation and human introduced errors. An attempt was made to combine the composition model with the strength model, but the variation of the strength data allowed no trend to be discerned.