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prayed solder/braze filler alloys for the joining of light metals

F Available) · January 2004 with 14 Reads

s publication

Bernhard Wielage Andreas Wank

38.82 · Technische Universität Chemnitz 19.28 · GTV Verschleiss-Schutz GmbH

Thomas Grund
27.64 · Technische Universität Chemnitz

RODUCTION Generally the established thermal spray technologies like flame or arc spraying can be used for the defined deposition of
braze filler metal layers. But for those processes used under atmospheric conditions the achieved quality of the solder/braze joints is low. A
ensity of defects like inclusions or oxides, pores and contaminations are not avoidable. The novel technique of the cold gas spraying (CGS)
with very low process temperatures. Therefore the heating of spray particles is reduced to a minimum. The produced coatings are free of
and show very low porosity. So investigations concerning the potential of CGS for the application of solder/braze filler metals are self-
t. In this work, substrates of different aluminium alloys (AA1050, AA3005, AA5754 and AA7022) are chosen. Depending on their particular
cation temperature, the used solder/braze filler materials are Al-, Zn-and Sn-based alloys. 2 SOLDERING / BRAZING Soldering and brazing

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rmalSee
joining
all › techniques. They
See all › are characterised
See all › by the process temperature T L , which has to be lower than the solidification temperatures
nd T2S2 of the partners to be joined, but2depending Download citation Share Download full-text PDF
Citations 10 References Figures on the material combination close to, equal to or higher than the melting temperature of
der/braze filler alloy. As the filler is partly or totally molten, interactions (diffusion processes that result in alloying) between the partners to be
and the filler material can occur. One major advantage in comparison to (conventional) welding processes is the possibility to join materials
ry different chemical compositions (like steel with copper) and, by using active brazing filler alloys, different bond types (like steel with
cs) [1]. Depending on the applied process temperature, soldering (< 450 °C), brazing (450 -900 °C) and high temperature brazing (> 900 °C)
ses are distinguished by standard [2].

ver the world's research

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2 Citations 10 References 2 Figures

arison of K Fv-factors of AlSi12 CGS coatings (p = 25 bar, m' = 17 Comparison of K F-factors for SnAg4Cu0.5 CGS coatings (powder feed
T = 400 °C, a = 20 mm). rate m' = 7.5 g/min).

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Grund, T.; Wank, A.; Wielage, B: Thermally sprayed solder/braze filler alloys for the joining of light met
Proceedings: XII. Workshop Plasmatechnik, TU Ilmenau (2004), pp. 39-48, ISBN 3-00-014314-9

THERMALLY SPRAYED SOLDER/BRAZE FILLER ALLOYS

FOR THE JOINING OF LIGHT METALS
B. Wielage, A. Wank, Th. Grund

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2/20/2019 (PDF) Thermally sprayed solder/braze filler alloys for the joining of light metals

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Institute of Composite
2 Citations 10 References Materials,
2 Figures Faculty of Mechanical Engineering, TU Chemnitz

1 INTRODUCTION

Generally the established thermal spray technologies like flame or arc spraying can be used
for the defined deposition of solder/braze filler metal layers. But for those processes used
under atmospheric conditions the achieved quality of the solder/braze joints is low. A high
density of defects like inclusions or oxides, pores and contaminations are not avoidable. The Ad
novel technique of the cold gas spraying (CGS) works with very low process temperatures.
Therefore the heating of spray particles is reduced to a minimum. The produced coatings are
free of oxides and show very low porosity. So investigations concerning the potential of CGS
for the application of solder/braze filler metals are self-evident.

In this work, substrates of different aluminium alloys (AA1050, AA3005, AA5754 and
AA7022) are chosen. Depending on their particular solidification temperature, the used
solder/braze filler materials are Al-, Zn- and Sn-based alloys.

2 SOLDERING / BRAZING

Soldering and brazing are thermal joining techniques. They are characterised by the process
temperature TL, which has to be lower than the solidification temperatures TS1 and TS2 of the
partners to be joined, but depending on the material combination close to, equal to or higher
than the melting temperature of the solder/braze filler alloy. As the filler is partly or totally
molten, interactions (diffusion processes that result in alloying) between the partners to be
joined and the filler material can occur. One major advantage in comparison to (conventional)
welding processes is the possibility to join materials with very different chemical
compositions (like steel with copper) and, by using active brazing filler alloys, different bond
types (like steel with ceramics) [1]. Depending on the applied process temperature, soldering
New
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New
See all › (< 450See°C),
all › brazingSee
(450
all › - 900 °C) and high temperature brazing (> 900 °C)Download
processes are
distinguished
2 Citations by standard
10 References 2 Figures[2].
citation Share Download full-text PDF

Brazing of aluminium alloys

New
The manufacturing of aluminium heat exchangers is the most common industrial CAB
(Controlled Atmosphere Brazing) process. Usually CAB processes are flux aided furnace
brazing processes under an inert shielding gas (mostly nitrogen). For the joining of Al-based
materials often AlSi alloys with melting temperatures between 595 and 610 °C are used as
braze fillers. More expensive AlSiGe alloys (Ge for lowering the melting temperature) are
used in vacuum brazing processes. Due to economical aspects their application is limited to
small volume production only [3].

Hot
37%

Lazada
Singapore
Aluminium CAB processes need fluxes. Fluxes have to cleanse the surfaces of the partners to
be joined and to destroy the natural alumina film (Al2O3) on top of them. The alumina
prevents the wetting by the braze filler material. So the flux agent additionally has to delay the
reformation of the alumina skin for at least the brazing time. Carrying out the brazing process
in an inert shielding gas atmosphere does not prevent the re-oxidation, because conventional
technical inert gas atmosphere contains up to 3 % oxygen. In the past chloridic and/or
fluoridic fluxes have mostly been in use, though their disadvantages are strong hygroscopic
nature and corrosive attack on the aluminium. The brazed assemblies had to be cleansed,
etched and passivated afterwards. Because of the additional costs and the ecologic risk in
using aggressive cleaning agents, chloridic and pure fluoridic fluxes are not often used in
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industrial
2 Citations applications
10 References any
more.
2 Figures
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Flux-free brazing processes (in vacuum or ultrasonically assisted) require high quality
surfaces and cannot be applied to all geometries and dimensions. Therefore their application
area is limited to small series productions or special applications. For Al materials the
industrially most frequently applied CAB process is the NOCOLOK® Flux CAB. It shows the
advantages of an easily controllable flux aided brazing process without the need of a post-
treatment by cleaning agents. The so called NOCOLOK® Flux agent mainly contains
potassium-fluorine-aluminate, which forms non-hygroscopic reaction products that cannot be
dissolved in water and do not cause corrosive attack on aluminium. In most cases (decorative
effect not important) a cleansing process after brazing is not necessary [4].

3 COLD GAS SPRAYING

Cold gas spraying (CGS) is part of the group of thermal spray (TS) processes. TS is capable
of coating defined surface areas of components with functional coatings (concerning
corrosion, wear, thermal and electrical behaviour, etc.) or of repairing worn out areas.
Generally all conventional TS processes are characterised by an energy source that melts or
warms up a feedstock material and accelerates the spray particles onto a substrates surface, on
which the coating forms. The substrate is not molten during the deposition process.
Conventional energy sources of TS processes are flames, electrical arcs and plasmas. Depen-
ding on specific process characteristics the feedstock can be in wire, rod or powder shape.

During the time of interaction between particles and gas flow thermal and kinetic energy is
transferred to the particles. Particle temperature and velocity at impact on the substrate
determine the particles deposition characteristics and thereby coating properties like
homogeneity, density, porosity, bond strength, etc. In high velocity (HV) spray processes
more kinetic and less thermal energy is transferred to the spray particles. As a consequence of
the particles high kinetic energy also warm solid particles can take part in the coating
formation process and low porosity is achievable. The thermal load of the spray particles
decreases, which results in less reactions with the spraying atmosphere.

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CGS 10
2 Citations is References
a border case of thermal
spraying and a consequent development of HV TS processes.
2 Figures
The spray particles temperature is far below the solidification temperature and their velocity
can (presently) amount to 1,200 m/s. CGS works by expansion of a process at high pressure
through a convergent/divergent nozzle with spray particle injection in front of the smallest
cross section. Heating of the process gas (T < 800 °C) results in increased particle velocities.
Though the physical effects of the deposition process are not fully understood by now, it is
known that the particles need to impinge on the substrate with a velocity exceeding a material

specific velocity to achieve a turn from abrasive effect to sticking [5,6]. However, GGS can
only be applied successfully for coating materials with high ductility. Especially pure ceramic
coatings cannot be produced.

In comparison to most other TS processes at atmosphere CGS permits manufacturing of

coatings with very low porosity and oxide content. Especially substrate near coating areas are
highly mechanically solidified. For coating materials with low thermal conductivity the bond
strength can be increased due to small areas of metallurgical interactions (at particle/substrate
as well as at particle/particle interfaces) due to local melting. Coatings with properties
comparable to bulk material can be produced with high reproducibility [7,8].

4 MATERIALS

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The aluminium
2 Citations alloys
10 References used in this work are listed along with their melting temperatures
2 Figures
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table 1. Also the filler materials assigned to the specific substrates and their working
temperatures are given.

Tab. 1 Used aluminium substrates and solder/braze filler

Substrate Melting Filler material Working

temperature (TS) temperature (TL)
SnAg4Cu0.5 226 °C
AA 1050 646 °C Zn 420 °C

AlSi12 578 °C
AA 3005 630 °C
AA 5754 610 °C
Zn 420 °C
AA 7022 545 °C
ZnAl5 380 °C
ZnAl15 440 °C

The powder feedstock used for CGS are analysed concerning their morphology (by SEM) and
chemical composition (by EDXS). The AlSi12 powder particles show homogeneous
distribution of aluminium and silicon phases, spherical shape and size between 1 and 35 µm.
EDXS analyses confirm the chemical composition of 12 wt.-% silicon in aluminium. The zinc
based powders are blends of pure zinc and pure aluminium powder (EDXS results: 100 wt.-%
zinc; 100 wt.-% aluminium). Both show non-spherical particle shape. The particle size
fractions are 10 µm < d < 60 µm (zinc) and 5 µm < d < 20 µm (aluminium powder). Beside
pure zinc powder, two composite powders are mechanically mixed: ZnAl5 (zinc, 5 wt.-%
aluminium) and ZnAl15 (zinc, 15 wt.-% aluminium). According to the manufacturer the
Sn95.5Ag4.0Cu0.5 powder shows spherical shape and a size fraction of 5 µm < d < 25 µm.

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2 Citations 10 References 2 Figures

5 EXPERIMENTAL

Coatings are produced using the CGS system Kinetic 3000 (CGT Cold Gas Technology
GmbH, Ampfing). The spraying process parameters gas pressure p, gas temperature T, spray
distance a and powder feed rate m’ are optimized by design of experiments applying 24
experiments for each powder. Each coating is built up to a thickness of approximately 100 µm
by moving the spray gun in meanders with 1 mm distance and spraying gun traverse velocity
0.35 m/s. For the CGS coating process using AlSi12 powder, also the influence of the
spraying gun traverse velocity is investigated. In table 2 the powder specific values of the
spraying parameters are given.

Tab. 2 Applied spraying parameters

filler metal alloy process gas process gas spray distance powder feed
pressure temperature rate
[bar] [°C] [mm] [g/min]
min Max min max min max min max
AlSi12 25 30 350 400 20 30 17 34,5
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SnAg4Cu0.5
2 Citations 10 References 15
2 Figures 30 100 250 20 40 7,5
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Zn 10 30 100 250 20 40 9 32,5

ZnAl5 10 30 100 250 20 40 8,5 31,5
ZnAl15 10 30 100 250 20 40 7 26

The soldering/brazing investigations concentrate on furnace processing with nitrogen

atmosphere using industrially applied flux agents. The process is optimized concerning
temperature-time function. For comparison samples with conventionally added filler materials
(roll plated or as wire) are also joined.

Both CGS coatings and solder/braze joints are characterized by means of optical microscopy,
SEM and EDXS analyses.

6 RESULTS

Production of CGS coatings

Depending on powder type and process parameters a different number of passes is necessary
to reach the desired coating thickness of 100 µm. For each powder there is a transition from
blasting to coating deposition depending on the process parameters. All coatings deposited by
the same powder show comparable surface roughness and low porosity. Figures 1 to 3 show
examples of the different coating types. The SEM investigations confirm very good bonding
between coatings and substrates, partially with deep penetration of spray particles into the
base material, especially in the case of the Sn based powder. Particularly the surfaces of
AlSi12 coatings are very rough, while the Zn and Sn based coatings are rather smooth. EDXS
analyses of both feedstock and coatings prove that no additional phases are formed and the

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2 Citations 10 References 2 Figures

chemical composition remains constant. Only Zn-Al coatings show a difference in the
composition of zinc and aluminium. The aluminium content is nearly doubled in comparison
to the feedstock composition, which points at a significantly higher deposition efficiency of
aluminium.

Fig. 1
CGS AlSi12 coating,
optical (a) and SEM
a 100 µm
b micrograph (b).

Fig. 2
CGS Zn5Al, optical
(a) and SEM
a 100 µm
b micrograph (b).

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2 Citations 10 References 2 Figures

Fig. 3
CGS SnAg4Cu0.5,
optical (a) and SEM
a 100 µm b micograph (b).

Assuming a constant coating density a factor K, which is proportional to the deposition

efficiency, can be defined as:

K = d / (N · m’) (1).

d: coating thickness [µm]

N: number of passes
m´: powder feed rate [g/min]

For constant powder feed rate KF already permits optimization of processing concerning
deposition efficiency:

KF = d / N (2).

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2 Citations 10 References 2 Figures

For including the gun traverse velocity v at constant powder feed rate into optimization
considerations it has to be imparted in the characteristic parameter KFv due to its influence on
the spraying time:

KFv = v · KF (3).

Generally CGS spraying with both high process gas temperature and pressure results in
highest K-factors. Particularly AlSi12 coatings are only deposited, if high gas temperatures
are applied. In figure 4 a comparison of the K-factors depending on processing conditions for
production of CGS AlSi12 coatings with process gas temperature of 400 °C is given.
Apparently low powder feed rates result in increased deposition efficiency. The highest
deposition efficiency is achieved for low levels of gas pressure, spray distance and powder
feed rate.

Fig. 4
Comparison of K-factors
for AlSi12 CGS coatings
using high process gas
temperature (400 °C)

The experiments concerning the influence of the gun traverse velocity show only small

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differences
See all ›
in morphology
See all ›
of the CGS AlSi12 coatings (velocities between 0.21 and 0.7
Download m/s). Share
citation Download full-text PDF
Therefore optimization
2 Citations 10 References 2 Figuresis done according to pure economical considerations. Figure 5
comprises the KFv-factors depending on the gun traverse velocity. A maximum value is found
for a velocity of 0.53 m/s. For further investigations the velocity yielding the highest
K-factors is used exclusively.

In contrast to AlSi12 Zn-based coatings are also formed using low process gas temperatures
(down to 100 °C). The maximum applied temperature in this case is 250 °C. The deposition
efficiency increases with rising gas temperature. Also high process gas pressure and low
powder feed rate contribute to increasing deposition efficiency.

Figure 6 comprises KF-factors for CGS coatings produced using Zn, ZnAl5 and ZnAl15
powders and both high process gas temperatures and high powder feed rate. The different
powder types do not show significantly different dependencies of deposition efficiency.
Generally high process gas pressure results in high KF-factors. In particular ZnAl15 are only
formed, if high gas pressure conditions are applied. Also for ZnAl5 highest deposition
efficiency is achieved for use of high process gas pressure. No difference depending on the
spraying distance of 20 mm and 40 mm is observed for this powder type.

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2 Citations 10 References 2 Figures

Fig. 5
Comparison of KFv-factors
of AlSi12 CGS coatings
(p = 25 bar, m’ = 17 g/min,
T = 400 °C, a = 20 mm).

Fig. 6
Comparison of KF-factors
for Zn-based CGS coatings
using high powder feed
rate and process gas
temperature (250 °C).

Also SnAg4Cu0.5 coatings can be produced using low process gas temperatures. However,
like in the case of Zn-based coatings, in case of low process gas temperature high process gas
pressure is necessary. For small spraying distances high deposition efficiency is achieved.

D t ll tit f il bl d l l d
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See all › Due See

to small
all › quantity
See allof
› available powder only very low powder feed rate is used. The
KF-factors 2 Figures deposited SnAg4Cu0.5 CGS coatings are given in figure 7.
of successfully Download citation Share Download full-text PDF
2 Citations 10 References

Fig. 7
Comparison of KF-factors
for SnAg4Cu0.5 CGS
coatings (powder feed rate
m’ = 7.5 g/min).

Production of solder/braze joints

The applicability of the produced CGS coatings for soldering/brazing processes is

investigated by CAB and atmospheric processes using heating plate or propane flame. With
respect to the desired application field of heat exchangers the specimens are joint with angle-

[9 10] (fi 8( )) h b CGS d

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See all › on-coupon

See all › geometry [9,10]
See all › (figure 8(a)), whereby CGS coated substrates are used as
coupons.
2 Citations The angles2 Figures
10 References are realized by 1 mm thick AA1050 strips. Download citation Share Download full-text PDF

Applying CAB in nitrogen atmosphere with NOCOLOK® flux perfect joints are produced
with CGS AlSi12 coatings. The results are comparable to conventional methods of filler
material addition like wires or roll plated coatings. In figure 8(b) an optical micrograph of a
brazing seam for application of optimized temperature-time function (10 min at 610 °C) is
given. In the braze joint only a negligible amount of defects like pores, inclusions or oxides
can be detected. By SEM analysis a perfect metallurgical bonding between filler and base
material is shown. EDXS analyses prove diffusion of silicon into the angle material. In the
braze seam the silicon content amounts to 6 wt.-%. The precipitates located at grain
boundaries are equal to those already in AA1050 substrates. The brazing seam microstructure
compares to that of cast material.

Fig. 8
Angle-on-coupon sample
(a) and optical
micrograph of the braze
seam (b) of an aluminium
braze joint using CGS
a b AlSi12 coating filler.
500 µm

coating

diffusion zone

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2 Citations 10 References 2 Figures substrate
100 µm

Fig. 9 SEM image of a pure Zn CGS coated Fig. 10 Optical micrograph of a solder joint of
AA7022 sample after heat treatment AA1050-SiC(p) composite and AA5754
according to a furnace soldering process produced by ultrasonically assisted
(solder temperature 450 °C). soldering using pure Zn CGS coating
filler.

Zn-based CGS coatings do not permit production of high quality joints by CAB in nitrogen
atmosphere and addition of different fluoridic Cs-based fluxes. Also tests performed under
atmospheric conditions do not yield successful bonding. Always the wetting of the uncoated
aluminium angle failed. Figure 9 shows a SEM micrograph of an AA 7022 sample coated
with pure zinc after a heat treatment identical to the soldering process. Differences in
comparison to ZnAl5 and ZnAl15 CGS coatings are not observed. Flux-free ultrasonically
assisted soldering, however, produces perfect joints. An optical micrograph of a joint between
AA1050 and AA5754-SiC(p) is given in figure 10.

All experiments on the solderability of specimens coated with CGS Sn-based filler coatings

f il d D d i b di ld b hi d [11]
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SeeDue
all › to dewetting
See all no
› bonding could be achieved [11]. Download citation Share Download full-text PDF
2 Citations 10 References 2 Figures

7 SUMMARY AND DISCUSSION

AlSi12 Zn-Al and SnAg4Cu0.5 CGS coatings are successfully deposited on different
aluminium alloy substrates. The coatings show identical chemical composition to the applied
powder feedstock. For production of AlSi12 coatings comparatively high process gas
temperature and pressure need to be used due to its low ductility. Low powder feed rate is
beneficial to achieve maximum deposition efficiency. The investigations on the influence of
the spraying gun traverse velocity on AlSi12 coating properties yield no differences.
However, deposition rate and efficiency are strongly affected.

Zn-based feedstock (pure zinc, ZnAl5 and ZnAl15 blends) permits CGS coating production
even at low process gas temperature or pressure. Just as for AlSi12 also for processing of Zn-
based powders increased deposition efficiency is observed for low powder feed rate. EDXS-
analyses prove a strong increase of aluminium content in comparison to the used ZnAl5 and
ZnAl15 feedstock, which may not only be attributed to the different stress-strain behaviour
and density but also to powder properties like particle size. In the case of the applied powder
blend the zinc particles have three times larger diameter, i.e. roughly ten times larger volume
and three times higher density compared to the aluminium particles, i.e. all in all 30 times
higher mass of zinc particles. Therefore acceleration of aluminium particles occurs more
effectively, which may result in a larger amount of particles reaching over-critical velocity.
The applied SnAg4Cu0.5 feedstock permits production of dense CGS coatings both by low or
high process gas temperatures and pressures due to tin’s high ductility and low melting
temperature range.

For AlSi12 and Zn-based filler metal coatings a metallurgical reaction between the aluminium
substrates and the coatings occurs during the soldering/brazing processes. As the flux agents
do not approach the interface between coatings and substrate the natural oxide layer on top of
the aluminium substrates must have been destroyed permitting its wetting by the filler melt.
Despite deep penetration of particles during coating formation dewetting of the aluminium
substrates is observed in the case of SnAg4Cu0.5 filler coatings.

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CGS 10AlSi12
2 Citations and
References Zn-based
2 Figures filler metal coatings permit production of perfect solder/braze
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joints by using a flux aided CAB process in nitrogen atmosphere or flux-free ultrasonically
assisted soldering under atmospheric conditions.

8 ACKNOLEDGMENTS

The authors thank Mr. Grasme (OBZ Dresel & Grasme GmbH, Bad Krozingen, Germany) for
support by supplying the spraying equipment and consumables. A further thank applies to
Dr. Türpe (Behr GmbH & Co. KG, Stuttgart, Germany) for his advice and comparative CAB
investigations.

9 REFERENCES

[1] Wittke, K., W. Scheel, G. Köhler: Schweißen oder Übersoliduslöten?, DVS Berichte
212, 2001, S. 335-341
[2] N.N.: DIN ISO 857-2 (planned as a substitution for DIN 8505): Schweißen und
verwandte Prozesse - Begriffe - Teil 2: Weichlöten, Hartlöten und verwandte Begriffe,
DIN Deutsches Institut für Normung e.V., 2003

[3] B l H J H W S id k B Wi l L M i Al i i
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all › H.-J., H.-W.
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Martinez: Aluminiumlöten bei 500 °C -
2 Citations Eigenschaften
10 References von ZnAl-Verbindungen, DVS
2 Figures Berichte 212, 2001, S. 214-217
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®
[4] N.N.: Der NOCOLOK Flux Lötprozess; Solvay Fluor und Derivate GmbH,
download von http://www.solvay.com, 10/2003
[5] Stoltenhoff, T., H. Kreye, W. Krömmer, H. J. Richter: Kaltgasspritzen - vom
thermischen Spritzen zum kinetischen Spritzen, Tagungsband 5. Kolloquium
Hochgeschwindigkeitsflammspritzen, Erding, 2000, S. 29-38
[6] Stoltenhoff, T., J. Voyer, H. Kreye: Kaltgasspritzen - Stand der Technik und Anwen-
dungsmöglichkeiten, Proceedings International Thermal Spray Conference 2002,
Essen, D, DVS-Verlag, Düsseldorf, 2002, S. 366-374
[7] Papyrin A.-N., V.-F. Kosarev, S.-V. Klinkov, A.-P. Alkimov: Wechselwirkungen
zwischen Hochgeschwindigkeitspartikeln und Substraten beim Kaltgasspritzen,
Proceedings International Thermal Spray Conference 2002, DVS-Verlag Düsseldorf,
2002, S. 380-384
[8] Vlcek, K.-J.: Untersuchungen der Charakteristika des kinetischen Kompaktierens von
Pulver nach dem Cold-Spray-Prozess, Werkstoffwissenschaftliche Schriftenreihe
RWTH-Aachen, Band 58 (Dissertation), Verlag Mainz, 2000
[9] McCubbin, J.G.: NOCOLOK® Flux Brazing of Aluminium, AFC Holcroft - Eighth
Annual Invitational Aluminum Brazing Seminar, Detroit, 2003
[10] Schwiegel, M., C. Meurer, H.-W. Swidersky: Compatibility of Refrigerant R134a and
PAG Oil in the Presence of Post-Braze Flux Residue from Cesium-Containing Fluxes
(NOCOLOK® Cs Flux), AFC Holcroft - Eighth Annual Invitational Aluminum
Brazing Seminar, Detroit, 2003
[11] Grund, T.: Spritztechnische Applikation von Loten zum Fügen von Leichtmetallen,
Schriftenreihe: Werkstoffe und Werkstofftechnische Anwendungen, Hrsg.: B.
Wielage, Band 17, 2004, ISSN 1439-1597

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2 Citations 10 References 2 Figures

s (2) References (10)

esidue may cause corrosion in the joint as well ( Hansen et al., 2009). Flux-less aluminum soldering has been investigated via various
( Gickler et al., 2003) including mechanical rubbing of aluminum surface with molten solder ( Williams, 1957), ultrasonic bath soldering (
1973;Bullock, 1990), and thermal spraying ( Wielage et al., 2004 ). These reported flux-less soldering processes employ zinc-based solders
e good wetting in reflow over the aluminum surface ( Suganuma et al., 2009). ...

irect soldering of aluminum by ultrasonic surface activation

Full-text available
MATER PROCESS TECH
h Gheybi · Teiichi Ando · Zhiyong Gu

ow abstract

ution Microstructural Investigations of Interfaces Between Light Metal Alloy Substrates and Cold Gas-Sprayed Coatings

J THERM SPRAY TECHN

Grund · Harry Podlesak · Andreas Wank · Bernhard Wielage

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