Effect of ZrO2 Nanomaterials on Wettability and Interfacial Characteristics of Al-19Cu-11Si-2Sn Filler Metal for Low Temperature Al to Cu Dissimilar Brazing
Abstract
:1. Introduction
2. Materials and Methods
2.1. Preparation of ZrO2 Reinforced Filler Metal
2.2. Dissimilar Al/Cu Brazing
2.3. Characterization of ZrO2-reinforced Filler Metal
2.3.1. Microstructure
2.3.2. Brazeability
2.3.3. Mechanical Properties
3. Results and Discussion
3.1. Analysis of the Filler
3.1.1. Microstructure of ZrO2-Reinforced Al-19Cu-11Si-2Sn Filler Metals
- (1)
- Local change in the temperature of solidification front influencing the growth of α-Al phase.
- (2)
- The ZrO2 nanomaterials reduces the diffusion of atoms to the surface of the growing Si and CuAl2 phase.
- (3)
- Engulfed ZrO2 nanomaterials onto CuAl2 or Si phase increases the free energy of their growth by distortion and thus reducing the driving force for growth.
- (4)
- Pinning of the solidification front by ZrO2 nanomaterials is explained by the Gibbs-Thomson effect.
3.1.2. Spreading Analysis of ZrO2 Reinforced Al-19Cu-11Si-2Sn Filler
3.1.3. Mechanical Properties of ZrO2 Reinforced Al-19Cu-11Si-2Sn Filler
3.2. Aluminum to Copper Dissimilar Brazing
3.3. Analysis of the Al/Cu Brazed Joint
3.3.1. Interface Analysis
3.3.2. Tensile Properties of the Brazed Joint
3.3.3. Fracture Analysis of the Brazed Joint
4. Conclusions
- (1)
- SEM analysis shows a significant size reduction in Si particles and CuAl2 IMC with the addition of ZrO2 nanomaterials. This phenomenon was explained using ZrO2 nanomaterial-induced phase growth control during solidification of the Al-19Cu-11Si-2Sn filler alloy. TEM confirms the presence of ZrO2 nanomaterials along the surface of Si particles and CuAl2 IMC justifying phase growth control of nanomaterials.
- (2)
- Addition of ZrO2 nanomaterials increases the spreading ratio of filler on Cu and Al substrates. Furthermore, ZrO2 nanomaterials added to Al-19Cu-11Si-2Sn filler showed better mechanical properties in terms of microhardness and tensile properties.
- (3)
- The joints with varying input power and brazing time demonstrated a good bonding for 40 kW input power for 6 and 8 seconds.
- (4)
- Interface analysis of joint brazed at 40 kW, 8 seconds with Al-19Cu-11Si-2Sn and Al-19Cu-11Si-2Sn-ZrO2 demonstrated the formation of continuous Cu9Al4 reaction layer and discontinuous Al2Cu IMC on the Cu side, and formation of an inter-diffusion layer on the Al3003 side. However, a thin IMC and inter-diffusion layer is formed using Al-19Cu-11Si-2Sn-ZrO2 filler. ZrO2 nanomaterials in the filler are responsible for interface modification by surface adsorption phenomenon.
- (5)
- The tensile test results of the brazed joint justified the importance of ZrO2 nano-reinforced Al-19Cu-11Si-2Sn filler to join Al and Cu joints. Tensile strength increased linearly with the concentration of ZrO2 nanomaterials in filler alloy. Joints with 0.05 and 0.1 wt. % ZrO2 added filler shows base metal fracture confirming sound joint.
- (6)
- Fracture analysis of the brazed joint shows that ZrO2 nanomaterials adsorbed on Al2Cu IMC block the crack propagation along the interface which leads to crack branching. In filler without ZrO2 nanomaterials, cracks propagated through the filler metal leading to fracture.
Author Contributions
Funding
Conflicts of Interest
References
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Mark | Composition (at. %) | Phase | |||
---|---|---|---|---|---|
Al | Si | Cu | Sn | ||
A | - | 100 | - | - | Si phase |
B | 65.3 | - | 34.7 | - | CuAl2 IMC |
C | 92.3 | 1.4 | 6.0 | 0.3 | Al rich phase |
D | 2.5 | 0.4 | 3.2 | 93.9 | Sn rich phase |
S.N0 | Samples | Micro Hardness (HV) | Tensile Properties | Quality Index(MPa) | ||
---|---|---|---|---|---|---|
Yield Strength (MPa) | Ultimate Tensile Strength (MPa) | % Elongation | ||||
1 | Al-19Cu-11Si-2Sn | 89.4 ± 1.2 | 98.2 ± 1.1 | 124.7 ± 2.3 | 1.9 ± 0.2 | 167.2 |
2 | Al-19Cu-11Si-2Sn-0.03ZrO2 | 93.4 ± 0.9 | 103.4 ± 2.1 | 132.4 ± 1.1 | 2.2 ± 0.3 | 182.9 |
3 | Al-19Cu-11Si-2Sn-0.05ZrO2 | 107.8 ± 1.3 | 117.3 ± 1.7 | 157.4 ± 4.1 | 2.9 ± 0.1 | 225.6 |
4 | Al-19Cu-11Si-2Sn-0.1ZrO2 | 108.1 ± 1.4 | 123.4 ± 1.4 | 162.3 ± 3.3 | 2.9 ± 0.2 | 231.4 |
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Jung, D.-H.; Rajendran, S.H.; Jung, J.-P. Effect of ZrO2 Nanomaterials on Wettability and Interfacial Characteristics of Al-19Cu-11Si-2Sn Filler Metal for Low Temperature Al to Cu Dissimilar Brazing. Nanomaterials 2018, 8, 784. https://doi.org/10.3390/nano8100784
Jung D-H, Rajendran SH, Jung J-P. Effect of ZrO2 Nanomaterials on Wettability and Interfacial Characteristics of Al-19Cu-11Si-2Sn Filler Metal for Low Temperature Al to Cu Dissimilar Brazing. Nanomaterials. 2018; 8(10):784. https://doi.org/10.3390/nano8100784
Chicago/Turabian StyleJung, Do-Hyun, Sri Harini Rajendran, and Jae-Pil Jung. 2018. "Effect of ZrO2 Nanomaterials on Wettability and Interfacial Characteristics of Al-19Cu-11Si-2Sn Filler Metal for Low Temperature Al to Cu Dissimilar Brazing" Nanomaterials 8, no. 10: 784. https://doi.org/10.3390/nano8100784