Bonding of immiscible Mg and Fe via a nanoscale Fe2Al5 transition layer

Bonding of immiscible systems is difficult due to the sharp interface and high interfacial energy. A nanoscale transition layer with lattice matching to both sides could be a solution. To examine this hypothesis, Mg and Fe were successfully bonded by a precoated nanoscale Fe2Al5 layer, which in crystallographic terms matched well with both lattices. The interplanar mismatches of both Fe2Al5/Fe and Fe2Al5/Mg interfaces were less than 5% and both interfaces were found to be semicoherent.