Reliability studies of Cu/Al joints brazed with Zn–Al–Ce filler metals

This paper examines the effect of different Ce content on the properties and microstructures of Zn–22Al filler metals and Cu/Al brazing joints. The results indicate that, the spreading area on Cu substrates of Zn–22Al filler metal could be improved by 29.7% with the addition of 0.03 wt% Ce, whereas the oxidation resistance of the alloy increased significantly. The thermal behaviors of Zn–22Al filler metals were minimally influenced by the addition of Ce. The Zn–22Al–xCe filler metals show finer and more uniform microstructures when the added Ce content is in the range 0.03–0.05 wt%. Particularly, the addition of trace Ce into the Zn–22Al filler metal can refine the microstructures and decrease the thickness of the layer of intermetallic compounds produced in the Cu/Al brazing joints. Some bright (Zn,Al)–Ce intermetallic compounds particles were observed in the alloy when the Ce content exceeds 0.08 wt%. The results also indicate that the shear strength of Cu/Al joint brazed with Zn–22Al–0.05Ce is 30.3% higher than that of the Zn–22Al filler metal. Some hard and brittle Ce-bearing intermetallic compounds particles appear in the fracture surface when the Ce content is 0.25 wt%, which resulted in the weakening of the mechanical properties of Cu/Al brazing joints.

► Zn–22Al–xCe filler metals were designed for Cu/Al dissimilar metals brazing. ► The microstructure of Zn–22Al alloy was refined with the Ce addition. ► Ce addition improved the wettability and oxidation resistance of Zn–22Al alloy. ► The shear strength of Cu/Al brazing joints were improved with the Ce addition.