Solid state bonding of Fe and Al
2O
3 using an wüstite (written as FeO hereafter) interlayer was carried out by hot pressing at 1450 K for 3.6 ks in a vacuum of 10
−3 Pa under pressure of 29.3 MPa. The interfaces between bonded materials Fe/FeO/Al
2O
3 were investigated by means of EPMA, X-ray diffractometry and TEM. (001) plane of an Fe single crystal was oxidized, in order to determine the micro-compositional variation at the FeO/Fe interface by AES and XPS. The change in the ratio of the Auger peak heights
IO(503)⁄
IFe(703) and the chemical shift
ΔE of the Fe(2
p3⁄2) depending on the distance from the oxidized Fe surface were measured by using Ar
+ etching. It was found that in the region between 10 and 230 nm from the surface,
IO⁄
IFe was constant (=FeO). But in the region from 230 to 420 nm (T-region), it gradually and linearly decreased with increasing distance, until it began to drop exponentially to zero (=Fe). At the FeO/Al
2O
3 interface a new reaction layer about 6 μm in thickness was formed, which had a spinel type structure with the lattice parameter of 0.8171 nm showing broad diffraction lines. But electron diffraction photographs of the new reaction layer showed a hallow pattern. Tensile strength values of Fe/FeO/Fe and Al
2O
3/FeO/Al
2O
3 were 7.4 and 5.9 MPa, respectively, when the interlayer FeO was 300 μm in thickness, and they were 53.9 and 30.4 MPa, respectively, when the thickness was 50 μm. Fracture was observed not at the interfaces or in the T-region but in the brittle interlayer FeO in both cases of Fe and Al
2O
3. Therefore, it is clear that the T-region or the new reaction layer contributes to the FeO/Fe or FeO/Al
2O
3 bonding, respectively.
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