Effect of Filler Composition on the Brazing of Alumina to Copper Using Ultrasonic Wave

An ultrasonic wave was applied during brazing of alumina to Cu. First alumina was metallized by applying ultrasonicwave in braze bath. Then the metallized alumina was brazed with Cu using the same filler alloy. The filler used wereZn-Al alloys and Zn-Sn A     

Brazing of 422 stainless steel using the AWS classification BNi-2 Braze alloy

The study of brazing 422 stainless steel (422SS) using the AWS classification BNi-2 braze alloy as the filler metal is evaluated in the study. The BNi-2 braze alloy demonstrates excellent wettability on the 422SS substrate for temperatures exceeding 1025 °C. The brazed joint is primarily comprised of the Ni-rich matrix and chromium boride. Additionally, the B–Cr–Fe precipitates are formed at the interface between the braze and 422SS. Some Kirkendall porosity is also observed in the braze close to the interface, due to nonsymmetrical interdiffusion between the braze and 422SS substrate. Shear strengths of brazed joints are varied from 306 to 481 MPa. The infrared brazed specimen shows the highest shear strength among all brazed specimens. Increasing brazing temperature and/or time result in decreased shear strength of the brazed joint.     

New process for brazing ceramics utilizing squeeze casting

A new joining process for ceramics to ceramics and ceramics to metals, SQ brazing, has been developed. This process utilizes squeeze casting; a brazing material is squeezed into the interface channel to be brazed and is solidified under a high pressure. This new process has several advantages, low cost, mass producibility, high interface strength and high reliability, no severe reaction, etc. Alumina to alumina and silicon nitride to silicon nitride brazing with pure aluminium are shown as examples. Alumina containing silica as a sintering additive brazed by a conventional method severely reacted with aluminium braze so that the joint strength was low. After SQ brazing, reaction was moderate and the strength almost reached that of the parent alumina. Silicon nitride could be brazed by SQ brazing. Although the simple SQ brazing could not make a strong interface, pre-oxidization treatment of silicon nitride increased the joint strength beyond 400 M Pa.     

Ni-Cr-P焊膏钎焊C/C复合材料的组织和性能

用真空熔炼、惰性气体雾化法制备Ni-Cr-P金属粉末,再加入有机黏结剂高速搅拌,制备Ni14Cr10P膏状活性钎料。用制备好的焊膏真空钎焊C/C复合材料,测试钎焊接头的剪切强度,通过OM,SEM,EDS,XRD等对钎焊接头界面组织结构进行分析。结果表明:在钎焊温度1000℃、保温时间0.5 h条件下,获得的接头剪切强度达到28.6 MPa,然后随着钎焊温度上升或保温时间延长,钎焊接头强度下降;通过界面组织结构分析发现焊膏可以增加钎料层与C/C复合材料表面的接触面积,有利于堵塞C/C复合材料表面的孔隙。焊后在界面处形成了交错分布的Cr碳化物相缓冲层,使得界面呈现热膨胀系数梯度增加的结构,有助于缓解热失配,提高C/C复合材料钎焊接头强度。     

Joining of Si3N4 using Ag57Cu38Ti5 brazing filler metal

Hot-pressed Si₃N₄ was joined using Ag₅₇Cu₃₈Ti₅ brazing filler metal at 1103 to 1253 K for 5 min in a vacuum. The interface reactions between Si₃N₄ and the brazing filler metal during brazing are reported. An important event is sufficient interface reaction, characterized by the formation of a layer of TiN with an appropriate thickness at the ceramic-filler interface. The joining strength of the butt joint depends on the interface reaction, and a maximum joining strength of 490 MPa measured by the four-point-bend method is achieved for the Si₃N₄-Si₃N₄ joint brazed at 1153 K for 5 min. It is also discussed how to design the best brazing filler metal for joining ceramic to ceramic or ceramic to metal.     

Microstructure and strength of brazed joints of Ti3Al-base alloy with different filler metals

The interfacial microstructure and properties of brazed joints of a Ti₃Al-based alloy were investigated in this paper to meet the requirements of the use of Ti₃Al-based alloy in the aeronautic and space industries. The effects of different brazing fillers on the interfacial microstructure and shear strength were studied. The relationship between brazing parameters and shear strength of the joints was discussed, and the optimum brazing parameters were obtained. The brazed joints were qualitatively and quantitatively analyzed by means of EPMA, SEM and XRD. The results showed that using a AgCuZn brazing filler, TiCu, Ti(Cu,Al)₂ and Ag[s,s] were formed, the shear strength of the joint was decreased because of the formation of TiCu and Ti(Cu,Al)₂; using a CuP brazing filler, Cu₃P, TiCu and Cu[s,s] were formed at the interface of the joint, the former two intermetallic compounds decreased the shear strength. The analysis also indicated that using the TiZrNiCu brazing filler, the optimum parameters were temperature T=1323 K, joining time t=5 min, and the maximum shear strength was 259.6 MPa. For the AgCuZn brazing filler, the optimum parameters were joining temperature T=1073 K, joining time t=5 min, and the maximum shear strength was 165.4 MPa. To the CuP brazing filler, the optimum parameters were joining temperature T=1223 K, joining time t=5 min, and the maximum shear strength is 98.6 MPa. Consulting the results of P. He, J.C. Feng and H. Zhou [Microstructure and strength of brazed joints of Ti₃Al-base alloy with NiCrSiB, Mater. Charact., 52(8) (2004) 309–318], relative to the other brazing fillers, TiZrNiCu is the optimum brazing filler for brazing Ti₃Al-based alloy.     

Reactive brazing of aluminium to aluminium-based composite reinforced with alumina borate whiskers with Cu interlayer

The microstructure of the joints formed by vacuum reactive brazing of aluminium to aluminium-based composite, with a copper interlayer was investigated. Al-Cu eutectic (Al₂Cu + Al) was the predominant phase at the interface. The maximum shear strength of the joint was 85 MPa. The results show that reactive brazing with a Cu interlayer can be used successfully for joining aluminium and aluminium-based composites reinforced with alumina borate whiskers.     

一种具有球晶组织的半固态Zn-Al合金钎料

通过熔炼、浇注以及等温热处理的方法制备了具有球晶组织的Zn-Al合金,并采用重熔实验、等温压缩实验和振动辅助半固态钎焊实验研究了半固态Zn-Al合金的固相率与温度的关系、压缩变形行为以及作为钎料的可钎焊性。结果表明:半固态Zn-Al合金在压缩变形时,具有较强的抗变形能力;作为钎料,在钎焊过程中其固相率能控制在(64±5)%范围内,所得钎焊接头中仅在钎缝边缘处界面上有少许氧化膜残留,而其他区域界面上的氧化膜都被彻底去除。     

The effect of interlayer metals on the strength of alumina ceramic and 1Cr18Ni9Ti stainless steel bonding

The effects of interlayers of molybdenum and copper on the strength of alumina ceramic and 1Cr18Ni9Ti stainless steel bonding with Ag₅₇Cu₃₈Ti₅ filler metal were investigated. The interfacial morphologies were observed and analysed by scanning electron microscopy and energy dispersive X-ray (EDX) analysis, respectively. The joint strength was examined by shear tests. When using a molybdenum interlayer, the joint strength could be greatly improved because molybdenum not only reduced the interfacial residual stress, but also did not affect the interfacial reaction between the ceramic and the filler metal, and the maximum value was obtained when it was about 0.1 mm thick. When using copper as an interlayer, the joint strength was not increased but decreased, because copper reduced the activity of titanium in the filler metal, resulting in an insufficient interfacial reaction between the ceramic and the filler metal and the formation of poor interfacial adhesion. Therefore, in selecting an interlayer metal to reduce or avoid interfacial residual stress in joining ceramics to metals, in which the interfacial reaction of ceramic and filler metal is important to the joints, the interaction of interlayer metal and filler metal must be considered.     

Brazing perovskite ceramics with silver/copper oxide braze alloys

In this study the feasibility of eutectic braze alloys based on the silver/copper oxide (Ag/CuO) system were investigated for use in joining lead magnesium niobate (PMN) ceramics. PMN was successfully brazed in air at 1050 and 1100°C using Ag/CuO alloys. The brazed samples had an average four-point-bend fracture strength of approximately 40 percent of the average monolithic PMN strength (with an actual value of 19 ± 11 MPa). The fracture strength was relatively constant for all brazing conditions tested. No significant reaction product layer was observed at the silver/PMN interface and the electrical properties of the PMN were changed only slightly by presence of the braze alloy interlayers.     

Interfacial microstructure and strength of brazed copper/porous copper foam towards the effect of porous copper foam pore density and brazing holding time

The porous copper foam was sandwiched between two coppers plate and then brazed using copper-tin (9.7 %)-nickel (5.7 %)-phosphorus (7 %) filler foil. Brazing process was conducted to joint copper/porous copper foam by evaluating the effect of porous copper foam pore densities [pore per inch (PPI)] and brazing holding times. The brazed joint interface of copper and porous copper foam was characterised using Field emission scanning electron microscopy and Energy-dispersive x-ray spectroscopy for the microstructure and elemental composition analysis, respectively. X-ray diffraction analysis was carried out on the shear fractured surfaces of brazed copper and porous copper foam for phase determination. The results exhibited distinct phases of copper (Cu), copper phosphide (Cu₃P), nickel phosphide (Ni₃P), and copper compound with tin (6 : 5) (Cu₆Sn₅). The filler layer was formed as an island-shaped that consists of copper phosphide and nickel phosphide. Prolong brazing holding time causes a thinner filler layer in brazing seam. While the non-uniform thickness of the filler layer was observed at different pore densities of porous copper foam. The shear strength of brazed copper/porous copper foam 15 PPI with a 10 min brazing holding time yield a maximum shear strength of 2.9 MPa.     

Zn-Al钎料固相率及组分对Cu/Al管磁脉冲-半固态复合辅助钎焊接头质量的影响初探

由于节能环保以及轻量化的要求,Cu/Al异种金属复合管件被广泛应用于各工业领域,为此探索一种Cu/Al管件间高效可靠的连接技术具有较大应用价值和研究意义。为了探究Cu/Al管半固态钎焊连接机理并优化相关工艺参数,基于新提出的磁脉冲-半固态复合辅助钎焊方法制备了Cu/Al异种金属管件钎焊接头,利用LS-DYNA分析了半固态钎料不同表观粘度参数下外管内壁的受力情况,采用材料力学拉伸试验机,能谱仪和电子探针显微分析仪研究了半固态Zn-Al系钎料固相率及组分对焊接接头质量的影响。结果表明:外管内壁所受压力幅值随着表观粘度的增大而减小,剪切应力随着表观粘度的增大而增大;半固态钎料固相率为0.8时钎料与母材间没有良好冶金结合,固相率为0.4时会导致钎料填充不足的缺陷。在二次放电电压7 kV,半固态Zn-Al钎料固相率为0.6的条件下,磁脉冲-半固态复合辅助钎焊工艺能够实现Cu/Al管的无钎剂有效连接;与Zn-3Al和Zn-22Al相比,Zn-15Al钎料制得的接头综合性能更好,是较为合适的Cu/Al管磁脉冲辅助半固态钎焊用Zn-Al钎料。     

Formation of the reaction zone between tin‐copper brazing fillers and aluminum‐silicon‐magnesium alloys: Experiments and thermodynamic analysis

A primary challenge in brazing is the controlled formation of phases resulting from interactions of elements of the liquid filler metal with those of the base material. The morphology of the brazed joint, which is decisive for the mechanical properties of the joint, is influenced by present elements and process parameters such as brazing temperature and time. Furthermore, the wetting of the base material is a crucial factor in joining of aluminum because of the low wettability of the alumina layer by molten brazing filler metals. In order to remove the alumina and prevent reoxidation of the substrate surface, the brazing process can be conducted in vacuum or inert gas atmosphere. Again, selection of process parameters is crucial for the quality of the brazed seam. In this work, we focus on the influence of the process parameters on the wetting behavior and the formation of aluminum‐copper phases theoretically by means of thermodynamic calculations using a CALPHAD database as well as by means of in‐situ observations in the large‐chamber scanning electron microscope (LC‐SEM) and by brazing experiments. Both the critical temperatures with respect to the wetting and the reaction kinetics as well as the crucial stages of the brazing process and the resulting phases were determined.     

活性钎焊法连接碳化硅陶瓷的连接强度和微观结构

采用三元Ag-Cu-Ti活性焊料连接常压烧结碳化硅陶瓷,研究了反应温度、保温时间等钎焊工艺对碳化硅陶瓷连接强度的影响,分析了连接界面的微观结构和反应产物. 实验结果表明,在实验范围内,钎焊温度和保温时间对碳化硅陶瓷的连接强度均有峰值,四点弯曲强度最高达到342MPa,随着钎焊温度的升高,界面反应层厚度增加,连接强度提高,但过高的钎焊温度引起焊料的挥发而使连接强度下降. 焊料中的活性元素Ti与碳化硅发生反应在连接界面形成均匀致密的反应层,反应层厚度约1μm,XRD和EDX能谱分析结果表明反应产物是TiC和Ti₅Si₃.     

Improving the strength of brazed joints to alumina by adding carbon fibres

The addition of short, bare, carbon fibres to a silver-based active brazing alloy (63Ag-34Cu-2Ti-1Sn) resulted in up to 30% improvement in the shear/tensile joint strength of brazed joints between stainless steel and alumina. The optimum fibre volume fraction in the brazing material was 12%. This improvement is attributed to the thinning and microstructural simplification of the alumina/braze reaction product (titanium-rich) layer, the softening of the brazing alloy matrix, the strengthening of the braze and the reduction of the coefficient of thermal expansion. The depth of titanium diffusion into the alumina was decreased by the fibre addition. The first two effects are due to the absorption of titanium by the fibres. This absorption resulted in less titanium in the brazing alloy matrix, a braze/fibre particulate reaction product (titanium-rich) on the fibres and the diffusion of titanium into the fibres. In contrast, the use of an active brazing alloy with a lower titanium content but without carbon fibres gave much weaker joints. This revised version was published online in November 2006 with corrections to the Cover Date.     

Infrared brazing Inconel 601 and 422 stainless steel using the 70Au-22Ni-8Pd braze alloy

Infrared brazing Inconel 601 and 422 stainless steel using the 70Au-22Ni-8Pd braze alloy is performed in the experiment. The brazed joint is primarily comprised of Au-rich and Ni-rich phases, and there is no interfacial intermetallic compound observed in the joint. The (Ni,Fe)-rich phase is observed at the interface between 422SS and the braze alloy, and the Ni-rich phase is found at the interface between the braze alloy and IN601. With increasing the brazing temperature and/or time, the microstructures of the brazed joint is coarsened. For the infrared brazed joint at 1050^∘C for 180 s shows the highest average shear strength of 362 MPa. In contrast, the shear strength of the infrared brazed joint is higher than that of the furnace brazed specimen due to coarsening of the microstructure in the furnace brazed joint.     

Joining of Si3N4/Si3N4 with CuNiTiB paste brazing filler metals and interfacial reactions of the joints

The joining of Si₃N₄/Si₃N₄ was carried out using CuNiTiB paste brazing filler metals. The maximum room-temperature three-point bend strength of the joints is 338.8 MPa. The cross-section microstructures of the joints and the element area distribution were examined by scanning electron microscope (SEM) equipped with wave dispersive X-ray spectroscopy (WDS). The phases appeared on the fracture surfaces of the joints were determined by means of X-ray diffraction analysis (XRDA) method. A model is established of the interfacial reactions between Si₃N₄ and the CuNiTiB brazing filler metals. With this model, the relationship between the joint strength and the interfacial reactions is discussed.     

The influence of brazing conditions on joint strength in Al2O3/Al2O3 bonding

The brazing of alumina ceramic to itself was performed using Ag₅₇Cu₃₈Ti₅ filler alloy. The bonding was carried out in a vacuum of 7 × 10^?3 Pa, and the joining conditions were at 1073, 1123, 1173, 1223, 1273 and 1323 K for 1.8ks under a pressure of 0.01 MPa, at 1123 K with a pressure of 0.01 MPa for 0, 0.3, 0.9, 1.8, 2.7 and 3.6 ks, and at 1123 K for 1.8 ks with pressures of 0, 0.01, 0.05, 0.10, 0.15, 0.20 and 0.30 MPa, to determine the effects of joining temperature, pressure and holding time on the joint strength. The joint strength was measured by shear tests. The interface microstructures and fractured surfaces after testing were observed by scanning electron microscopy (SEM). It was shown that the shear strength of Al₂O₃/Al₂O₃ joints was largely affected by the joining conditions; it first increased and then decreased with increasing joining temperature, pressure and holding time and depended mainly on the strength of interfacial reaction layer itself and the interface bonding strength between the reaction layer and the ceramic. The maximum joint strength was obtained when the reaction occurred under a suitable temperature, pressure and time, and the reaction layer thickness was about 2 μm. SEM observations revealed that there were four types of fracture and each kind corresponded to a different strength.     

Brazing of SiC to a wrought nickel-based superalloy using CoFeNi(Si, B)CrTi filler metal

Newly-developed CoFeNi(Si, B)CrTi brazing filler metal was used for joining of SiC to a wrought nickel-based superalloy (GH3044). The brazing alloy was fabricated into brazing foils by a rapid solidifying technique, and the brazing temperature was fixed at 1150 °C. The SiC/GH3044 joints using single interlayer Ni or triple interlayers of Ni/W/Ni showed very low strength, and this was because the Ni severely interfered with the normal reactions between the SiC and the brazing alloy. When using triple interlayers of Kovar/W/Ni for the SiC/GH3044 joining, the joint strength was remarkably elevated to 62.5-64.6 MPa. Kovar has a low coefficient of thermal expansion. Moreover, when Kovar was used as an interlayer neighboured to the brazed SiC, it basically ensured the normal interfacial reactions between the brazed SiC and the used brazing alloy. These two factors should account for the improvement of the joint strength.     

Microstructure and strength of high nitrogen steel joints brazed with Ni-Cr-B-Si filler

Brazing of high nitrogen austenitic stainless steels was carried out by using Ni-Cr-B-Si filler metal. The effects of brazing temperature (1020–1100°C) on the microstructure and shear strength of the joints were investigated. The results show that BN compounds with hexagonal structure are formed at the interface by the reaction of N from substrate and B from filler. The brittle Cr₅B₃ compounds with high microhardness are observed in the centre of brazing seam. The BN content increases and the Cr₅B₃ content decreases with the increase in brazing temperature. However, the content of BN compounds played a determinable role on the joint strength. The optimal shear strength of joints was 176.7?MPa when the joining temperature was 1020°C.