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A new approach to flux deposition for brazing aluminium by low pressure cold spraying

Tomasz Wojdat
Tomasz Wojdat
, 
Marcin Winnicki
Marcin Winnicki
 and 
Jaroslaw Pabian
Jaroslaw Pabian
   | Apr 20, 2023
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Published Online: Apr 20, 2023
Page range: 114 - 124
Received: Jan 10, 2023
Accepted: Mar 08, 2023
DOI: https://doi.org/10.2478/msp-2022-0048
Keywords
© 2022 Tomasz Wojdat et al., published by Sciendo
This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License.

Fig. 1

An exemplary roughness profile for the PFR 2 sample (DM). DM, digital microscope
An exemplary roughness profile for the PFR 2 sample (DM). DM, digital microscope

Fig. 2

Micrographs (SEM, BSE) of flux coatings: (A) PFR 1 and (B) PFR 2. 1 – substrate (AA3003), 2 – flux (Nocolok) coating. SEM, scanning electron microscope
Micrographs (SEM, BSE) of flux coatings: (A) PFR 1 and (B) PFR 2. 1 – substrate (AA3003), 2 – flux (Nocolok) coating. SEM, scanning electron microscope

Fig. 3

Micrograph (SEM, BSE) of the PFR 3 coating. 1 – substrate (AA3003), 2 – flux (Nocolok) coating. SEM, scanning electron microscope
Micrograph (SEM, BSE) of the PFR 3 coating. 1 – substrate (AA3003), 2 – flux (Nocolok) coating. SEM, scanning electron microscope

Fig. 4

(A) EDS analysis of the PFR 3 coating's surface and (B) elements distribution of aluminium, (C) fluorine and (D) potassium. Table – chemical composition of the coating depended on powder feed rate determined based on the surface EDS analysis. EDS, energy dispersive spectrometry
(A) EDS analysis of the PFR 3 coating's surface and (B) elements distribution of aluminium, (C) fluorine and (D) potassium. Table – chemical composition of the coating depended on powder feed rate determined based on the surface EDS analysis. EDS, energy dispersive spectrometry

Fig. 5

Results of the B-AlSi12 filler metal spreadability on AA3003 substrates
Results of the B-AlSi12 filler metal spreadability on AA3003 substrates

Fig. 6

Results of the B-AlSi12 filler metal wettability test on AA3003 substrates
Results of the B-AlSi12 filler metal wettability test on AA3003 substrates

Fig. 7

Cross-section (DM) of brazed joints for various samples: (A) PFR 1, (B) PFR 2 and (C) PFR 3. DM, digital microscope
Cross-section (DM) of brazed joints for various samples: (A) PFR 1, (B) PFR 2 and (C) PFR 3. DM, digital microscope

Fig. 8

Microstructure (SEM, BSE) of brazed joints (A) PFR 1, (B) PFR 2, (C) PFR 3 and phase precipitates of Si in the microstructure of (A) PFR1, (B) PFR 2 and (C) PFR 3 samples. 1 – solid solution dendrites α-Al, 2 – eutectic (α + Si), 3 – irregularly shaped intermetallic phase and 4 – coniferous Si phase precipitates. SEM, scanning electron microscope
Microstructure (SEM, BSE) of brazed joints (A) PFR 1, (B) PFR 2, (C) PFR 3 and phase precipitates of Si in the microstructure of (A) PFR1, (B) PFR 2 and (C) PFR 3 samples. 1 – solid solution dendrites α-Al, 2 – eutectic (α + Si), 3 – irregularly shaped intermetallic phase and 4 – coniferous Si phase precipitates. SEM, scanning electron microscope

Fig. 9

EDS of the PFR 1 sample presenting the (A) analysed region and (B) distribution of the elements: Si, (C) Fe, and (D) Mn (mag. 2,000×, 20 keV). EDS, elemental mapping
EDS of the PFR 1 sample presenting the (A) analysed region and (B) distribution of the elements: Si, (C) Fe, and (D) Mn (mag. 2,000×, 20 keV). EDS, elemental mapping

Fig. 10

SEM micrograph (BSE) of the PFR 1 sample with EDS analysis (magnification 2,000×, 20 keV). EDS, energy dispersive spectrometry; SEM, scanning electron microscope
SEM micrograph (BSE) of the PFR 1 sample with EDS analysis (magnification 2,000×, 20 keV). EDS, energy dispersive spectrometry; SEM, scanning electron microscope

LPCS process parameters during flux deposition

Powder feed rate, g/min Traverse speed, mm/s Gas preheating temperature, °C Gas pressure, MPa Standoff, mm Number of spray passes
4.5 20 200 05 10 1
6.3
8.5

Results of roughness and thickness measurements

Parameter Samples
PFR 1 PFR 2 PFR 3
Mean roughness Ra (μm) 16.1 24.3 35.7
Mean thickness t (μm) 5.3 16.2 83.5
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