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AbstractThe B2O3-SiO2-Al2O3-CaO brazing fluxes and slags were investigated by using X-ray photoelectron spectroscopy (XPS) and Fourier transform infrared spectroscopy (FTIR). The microstructure of the fluxes and slags and its transformation mechanism during the brazing process were investigated, especially the effect of ratio of B2O3to SiO2(B2O3/SiO2) on the microstructural transformation was analyzed. The results show that the structure units of the fluxes and slags are [BO4], [BO3], [SiO4], [AlO4] and [AlO6], and the network structure is a silicon-boron network structure. The O in the slags consist of bridged oxygen, non-bridged oxygen and free oxygen. During the brazing process, part of the [BO4] in slag combined with silica-oxygen network to form Si-O-B structure, which contribute to the network structure of slag, and another part of the [BO4] was transformed to [BO3]. The increase of (B2O3/SiO2) contribute to the transformation of [BO4] to [BO3], and more B2O3 take part in the interface reaction with the increase of (B2O3/SiO2). Therefore, the increase of (B2O3/SiO2) leads to the decrease in the viscosity of the slag, which is beneficial to the spreading behavior during the brazing process.

In this study, under the conditions of using tools at a high rotational speed (HRS) of 10,000 rpm and an ultra-high rotational speed (ultra-HRS) of 18,000 rpm, the produced welding heat input was utilized to weld two specimens of Al alloy 6061-T6 with 1.0 mm thickness and 316L SS with 0.8 mm thickness. The microstructural characteristics, mechanical properties, and electrochemical corrosion properties of the aluminum alloy–steel joints were analyzed. The higher tool offset forms an intermetallic compound layer of less than 1 µm at the Fe-Al interface on the advancing side (AS) at different speeds. This results in a mixed zone structure. The lower tool offset forms intermetallic compounds of only 2 µm. The formation of a composite material based on aluminum alloy in the weld nugget zone improves the hardness value. The intermetallic compounds are Fe3Al and FeAl3, respectively. It was observed that the formation of intermetallic compounds is solely related to the rotational speed, and the iron-rich intermetallic compounds produced under ultra-HRS parameters have higher corrosion resistance. When the tool offset is 0.55 mm, using the HRS parameters, the tensile strength is 220.8 MPa (about 75.9% of that of the base metal).

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Cu interlayers with thicknesses of 1, 1.5, and 2 mm were used to join niobium and AISI 304 steel. Fractures occurred in the weld, the Nb base metal, and the unmelted Cu interlayer when the Cu interlayer thickness was 1, 1.5, and 2 mm, respectively. When the thickness of the Cu interlayer was 1 mm, the weld microstructure consisted of austenite with Cu-rich particles along the austenitic grain boundaries and within the austenitic grains, a compositelike structure (the Fe2Nb lamellae and particles in a γ matrix) embedded with coarse Cu globules, and a mixture of bulk Fe7Nb6, Nb-rich dendrites, and Cu matrix. The bulk brittle Fe7Nb6 phase embrittled the joint. However, when the thickness of the Cu interlayer was 1.5 mm, the weld microstructure consisted of austenite with Cu-rich precipitates along the austenitic grain boundaries and a Cu-rich phase embedded with Nb-rich particles and dendrites. Solid-solution strengthening of Cu by Fe was responsible for the improved mechanical properties of the joint. The mixture of Nb-rich particles and dendrites in the Cu matrix was also helpful in enhancing the joint strength. Furthermore, when the thickness of the Cu interlayer was 2 mm, the weld microstructure consisted of austenite with Cu-rich precipitates along the austenitic grain boundaries and within the austenitic grains, an unmelted Cu interlayer, and Nb-rich particles and dendrites embedded in a Cu matrix. The unmelted Cu interlayer reduced the joint strength.