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Effect of ultrasonic power on the microstructure and mechanical properties of TC4 alloy ultrasonically brazed joint using Zn filler

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Abstract

In this study, TC4 alloys were brazed with ultrasonic assistance in air using pure Zn filler. The effect of ultrasonic power on the microstructure and mechanical properties of brazed joints was studied. The results show that the wetting of pure Zn filler on TC4 alloy is characterized by the formation of a TiZn3 intermetallic compound (IMC). The low ultrasonic powder of Mode I results in incomplete wetting of the substrate. Increasing the ultrasonic power changes spot wetting to surface wetting. A continuous TiZn3 IMC layer with cracks is observed when the ultrasonic powder is increased to Mode III. The grains of the filler inside the joint are refined from 5.54 µm to 4.00 µm when the ultrasonic power increases from Mode I to III. The shear strength of the brazed joint first increases and then decreases with an increase in the ultrasonic power. A maximum shear strength of 73.07 MPa is achieved when the ultrasonic power is in Mode II. The low joint strength at a high ultrasonic power is attributed to the cracks inside the TiZn3 IMC layer.

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Funding

This work is supported by the National Key R&D Program of China (No. 2020YFE0205303) and the National Natural Science Foundation of China (No. 51574099).

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Authors and Affiliations

  1. State Key Laboratory of Advanced Welding and Joining, Harbin Institute of Technology, Harbin, 150001, China

    Xuesong Liu, Zhengwei Li, Zhiwu Xu & Jiuchun Yan

Authors
  1. Xuesong Liu
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  2. Zhengwei Li
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  3. Zhiwu Xu
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  4. Jiuchun Yan
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Contributions

Xuesong Liu involved in methodology and funding acquisition; Zhengwei Li involved in completion of experiment and simulation, paper writing and project management; Zhiwu Xu involved in modification and funding acquisition; Jiuchun Yan involved in conceptualization.

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Correspondence to Zhiwu Xu.

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Highlights

1. TC4 alloy was successfully ultrasonically brazed using a pure Zn filler within extreme short time of 5 s.

2. The wetting of Zn on TC4 was realized by forming a TiZn3 intermetallic compound at the bonding interface. A TiZn3 layer with a thickness of less than 6 µm formed at 2/3 rated ultrasonic power, which resulted in a high joint strength of 73.07 MPa. Rated ultrasonic power of 1000 W leads to a TiZn3 layer thicker than 10 µm, which contains cracks and is detrimental to the joint strength. 

3. The grains of the Zn filler could be remarkably refined at increased ultrasonic power.

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Liu, X., Li, Z., Xu, Z. et al. Effect of ultrasonic power on the microstructure and mechanical properties of TC4 alloy ultrasonically brazed joint using Zn filler. Int J Adv Manuf Technol 119, 4677–4691 (2022). https://doi.org/10.1007/s00170-022-08649-8

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  • DOI: https://doi.org/10.1007/s00170-022-08649-8

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