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Abstract

This paper outlines issues associated with gas-shielded braze welding of CU-ETP copper with austenitic steel X5CrNi18-10 (1.4301) using a consumable electrode. The possibilities for producing joints of this type using innovative low-energy welding methods are discussed. The paper provides an overview of the results of metallographic and mechanical (static shear test, microhardness) tests for braze welded joints made on an automated station using the Cold Metal Transfer (CMT) method. Significant differences in the structure and mechanical properties are indicated, resulting from the joint configuration and the type of shielding gas (argon, helium).

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Authors and Affiliations

T. Wojdat
ORCID: ORCID
P. Kustroń
A. Margielewska
M. Stachowicz
ORCID: ORCID
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Abstract

In the paper, verification of welding process parameters of overlap joints of aluminium alloys EN AW-6082 and EN AW-7075, determined on the grounds of a numerical FEM model and a mathematical model, is presented. A model was prepared in order to determine the range of process parameters, for that the risk of hot crack occurrence during welding the material with limited weldability (EN AW-7075) would be minimum and the joints will meet the quality criteria. Results of metallographic and mechanical examinations of overlap welded joints are presented. Indicated are different destruction mechanisms of overlap and butt joints, as well as significant differences in their tensile strength: 110 to 135 MPa for overlap joints and 258 MPa on average for butt joints.

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Authors and Affiliations

T. Wojdat
ORCID: ORCID
P. Kustroń
K. Jaśkiewicz
M. Zwierzchowski
A. Margielewska
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Abstract

On the basis of research, the mechanisms of dissolution and erosion during brazing of aluminium alloys and the influence of these phenomena on brazed joints of heat exchangers are presented. A number of factors have been identified that affect the formation of these phenomena during brazing aluminium alloys, these include : the maximum temperature and holding time at brazing temperature, and the type and amount of filler metal. The research was supported by examples of dissolution and erosion phenomena during series production of aluminium heat exchangers using three brazing profiles (normal, hot and very hot). It has been found that the dissolution of the engine radiator components during brazing, is from 18 to 68%, depending on the brazing profile used. For a very hot profile, erosion in part of the brazed exchanger, even destroys (removes) thin elements of the cooling fins.
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Bibliography

[1] E . Frąckowiak, W. Mroziński, Using flame brazing technology for producing aluminum automotive heat exchangers, Welding Technology Review 9, 57-62 (2007).
[2] Z. Mirski, K. Granat, A. Misiek, Brazing of aluminum heat exchangers in the automotive industry, Spajanie materiałów konstrukcyjnych 2, 32-34 (2015).
[3] D . Pritchard, Soldering, Brazing, Welding; Crowood Press. (2001).
[4] Z. Mirski, J. Pabian, Modern trends in production of brazed heat exchangers for automotive industry. Welding Technology Review 89 (8), 5-12 (2017).
[5] J. Pilarczyk (Ed.), Engineer’s Guide: Welding, 2, WNT, Warszawa (2014).
[6] K . Ferjutz, J.R. Davis. ASM Handbook 6, Welding, Brazing, and Soldering. 10th ed. ASM International; (1993).
[7] M. Motyka, L. Orman, M. Lech-Grega, M. Nowak, Advanced technics in analysis of quality problems in aluminium brazed heat exchangers, Rudy i Metale Nieżelazne 7 (2010).
[8] J. Nowacki, M. Chudziński, P. Zmitrowicz, Brazing in Mechanical Engineering, WNT, Warszawa (2007).
[9] K . Hyun-Ho, L. Soon-Bok, Effect of a brazing process on mechanical and fatigue behavior of alclad aluminum 3005, Journal of Mechanical Science and Technology 26 (7), 2111-2115 (2012).
[10] A . Sharma, S.H. Lee, H.O. Ban, Y.S. Shin, J.P. Jung, Effect of various factors on the brazed joint properties in Al brazing technology, Journal of Welding and Joining 34 (2), 30-35 (2016).
[11] P.K. Velu, Study of the Effect of Brazing On Mechanical Properties of Aluminum Alloys For Automotive Heat Exchangers; A Thesis Submitted to the Faculty of Purdue University. In Partial Fulfillment of the Requirements for the Degree of Master of Science in Mechanical Engineering Purdue University Indianapolis, Indiana, USA (2017).
[12] M. Nylén, U. Gustavsson, W.B. Hutchinson, A. Örtnäs, Mechanistic Studies of Brazing in Clad Aluminium Alloys, Materials Science Forum 217-222, 1703-1708 (1996).
[13] M. Nylén, U. Gustavsson, W.B. Hutchinson, Å. Karlsson, The Mechanism of Braze Metal Penetration by Migration of Liquid Films of Aluminium Alloys, Materials Science Forum 331-337, 1737-1742 (2000).
[14] T. Yiyou, T. Zhen, J. Jianqing, Effect of Microstructure on Diffusional Solidification of 4343/3005/4343 Multi-Layer Aluminum Brazing Sheet. The Minerals, Metals & Materials Society and ASM International (2012).
[15] M. Nylén, U. Gustavsson, W.B. Hutchinson, Å. Karlsson, H. Johansson, Mechanisms of Erosion during Brazing of Aluminium Alloys, Materials Science Forum 396-402, 1585-1590 (2002).
[16] T. Izumi, T. Ueda, Influence of Erosion Phenomenon on Flow Behavior of Liquid Al-Si Filler Between Brazed Component; 13th International Conference on Aluminum Alloys (ICAA13) Pittsburgh (2012).
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Authors and Affiliations

Z. Mirski
1
ORCID: ORCID
J. Pabian
2
ORCID: ORCID
T. Wojdat
1
ORCID: ORCID

  1. Wroclaw University of Science and Technology, Faculty of Mechanical Engineering, Department of Metal Forming, Welding and Metrology, 27 Wybrzeże Wypiańskiego, 50-370 Wrocław, Poland
  2. Research & Development, MAHLE Behr Ostrów Wielkopolski
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Abstract

Thermal spraying methods are commonly used to regenerate damaged surface or change materials surface properties. One of the newest methods is cold spraying, where coating is deposited of material in the solid state. Therefore shape and size of the powder particles are very important parameters. The article presents the influence of copper powder morphology on mechanical properties of the coatings (adhesion, hardness, Young’s modulus) deposited with the Low Pressure Cold Spraying method on the AA1350 aluminium alloy substrate. The coatings were deposited using two commercially available copper powders with spherical and dendritic morphology and granulation of –40+10 µm. The bond strength of coatings was determined with the pull off method, the hardness with the Vickers method at load of 2.94 N, while the Young’s modulus through measurement of nanoindentation. Microstructure of the coatings was analysed using the light and scanning electron microscopy (SEM). Shape of the powder influences mechanical properties of the coating significantly. The coatings deposited with dendritic powder had low mechanical properties, hardness of the 81 HV0.3 order and adhesion of about 4 MPa. However changing powder morphology to spherical increased hardness of the coating to 180 HV0.3 and adhesion to 38.5 MPa.
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Authors and Affiliations

D. Grygier
1
ORCID: ORCID
M. Rutkowska-Gorczyca
1
ORCID: ORCID
M.G. Winnicki
2
ORCID: ORCID
T. Wojdat
2
ORCID: ORCID

  1. Wroclaw University of Science and Technology, Faculty of Mechanical Engineering, Department of Vehicle Engineering, Wybrzeże Wyspiańskiego 27, 50-370 Wrocław, Poland
  2. Wroclaw University of Science and Technology, Faculty of Mechanical Engineering, Department of Metal Forming, Welding and Metrology, Wybrzeże Wyspiańskiego 27, 50-370 Wrocław, Poland

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