Si particulate-reinforced ZnAl based composites joints of hypereutectic Al50Si alloys by ultrasonic-assisted soldering

• Hypereutectic AlSi alloys were joined using Zn5Al filler metal at only 420 °C in air without flux.
• Oxidation of hypereutectic AlSi alloys at the liquid/solid interface was removed by ultrasound.
• Si particulate-reinforced ZnAl composites joints could be obtained by ultrasonic-assisted soldering.
• The maximum strength of joints was ~ 108 MPa and then the fracture mainly occurred in the base metal.

Hypereutectic AlSi alloy plates were joined by ultrasonic-assisted flux-less method using Zn5Al filler metal at 420 °C in air. The influence of ultrasonic time on the microstructure and mechanical property of joints was investigated. The introducing of ultrasonic into soldering processes had effects on accelerating Si particles distribution in a Zn-based filler metal, and also affected the solidification microstructures of ZnAl alloys. The shear strength of joints had correlation with the distribution of Si particles and types of ZnAl alloys, and increased with the ultrasonic time. The highest average shear strength of joints reached to ~ 108 MPa, and the fracture mainly occurred at the base metal of Al50Si rather than the Si particulate-reinforced ZnAl based composites joints, indicating the strength of joints was stronger than that of Al50Si based metal.

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