Effect of Al Content on the Microstructure and Properties of Zn-Al Solder Alloys

To obtain Cu/Al brazing materials with better overall performances, scanning electron microscopy, X-ray diffraction, and electrochemical testing were used to analyze the influences of trace Ag elements on the microstructure and properties of Zn − 22Al − xAg filler metals. The results show that the liquid phase temperature of Zn − 22Al − xAg is about 450°C, and the trace addition of the Ag element has little effect on the melting point of the filler metal. When the Ag content was varied from 0 − 1.2 wt.%, the reticulated eutectic crystals in the microstructure of as − cast Zn − 22Al − xAg gradually began to connect to form a larger reticulated structure, and the phenomenon of grain − boundary aggregation became more and more obvious in the extruded-state alloy. In addition, when the Ag content was 0.8 wt.%, the spreading area of the filler metal on the Cu plate increased by 30.45% compared with that without Ag. After brazing, the thickness of the compounds in the interfacial layer along the filler metals/Cu decreased significantly, the shape of the compounds was more regular, and the shear strength of the brazed joints reached the maximum value of 40.08 MPa, but the corrosion resistance of the filler metal was slightly decreased compared with that of the Zn-22Al at the same time.

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Models for the Design and Optimization of the Multi-Stage Wiredrawing Process of ZnAl15% Wires for Spray Metallization

del Rey,

Guerrero-Vacas,

Comino

et al. 2024

Materials

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Metallization, a process for applying anti-corrosion coatings, has advantages over hot-dip galvanizing, such as reduced thermal stress and the ability to work “in situ”. This process consists of the projection of a protective metal as coating from a wire as application material, and this wire is obtained by multi-stage wiredrawing. For the metallization process, a zinc–aluminum alloy wire obtained by this process is used. This industrial process requires multiple stages/dies of diameter reduction, and determining the optimal sequence is complex. Thus, this work focuses on developing models with the aim of designing and optimizing the wiredrawing process of zinc–aluminum (ZnAl) alloys, specifically ZnAl15%, used for anti-corrosion applications. Both analytical models and numerical models based on the finite element method (FEM) and implemented by computer-aided engineering (CAE) software Deform 2D/3D v.12, enabled the prediction of the drawing stress and drawing force in each drawing stage, producing values consistent with experimental measurements. Key findings include the modeling of the material behavior when ZnAl15% wires were subjected to the tensile test at different speeds, with strain rate sensitivity coefficient m = 0.0128, demonstrating that this type of alloy is especially sensitive to the strain rate. In addition, the optimal friction coefficient (µ) for the drawing process of this material was experimentally identified as µ = 0.28, the ideal drawing die angle was determined to be 2α = 10°, and the alloy’s deformability limit has been established by a reduction ratio r ≤ 22.5%, which indicates good plastic deformation capacity. The experimental results confirmed that the development of the proposed models can be feasible to facilitate the design and optimization of industrial processes, improving the efficiency and quality of ZnAl15% alloy wire production.

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Effect of Al Content on the Microstructure and Properties of Zn-Al Solder Alloys

Cited by 4 publications

References 45 publications

Development of Zn–22Al–xAg filler metals for brazing 6061 aluminum alloy to T2 copper

Development of Zn–22Al–xAg filler metals for brazing 6061 aluminum alloy to T2 copper

Development of Zn–22Al–xAg filler metals for Brazing 6061 aluminum alloy to T2 copper

Models for the Design and Optimization of the Multi-Stage Wiredrawing Process of ZnAl15% Wires for Spray Metallization

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