Acoustic cavitation-induced microstructure evolution in ultrasonically brazed Al/Cu joints using Zn-Al alloy fillers

Tailoring the phase constitutions of the interfacial reaction layers under the assistance of ultrasonic vibration is a convenient method to fabricate high-strength Al/Cu brazing joints. In this study, 1060-Al and T2-Cu dissimilar metals were ultrasonically brazed with Zn-3Al (wt. %) filler metals. Effects of ultrasonic brazing time on the microstructure and mechanical properties of joints were investigated. Results showed that the CuZn₅ intermetallic compound (IMC) layer and Cu-based diffusion layer were created on the Cu substrate surface in the joint ultrasonically brazed at 400 ℃ for 2 s. However, the CuZn₅ IMC layer was gradually transformed into a thin Al_4.2Cu_3.2Zn_0.7 IMC layer by increasing the ultrasonic vibration time to 15 s. A well-matched coherent interface was formed between the Al_4.2Cu_3.2Zn_0.7 ternary phase and the Cu-based diffusion layer. The phase transition of the Cu-side interfacial layer correlated closely with the acoustic cavitations induced super-saturation regions near the Cu substrate surface. The measured tensile strength of the Al/Zn-3Al/Cu joint ultrasonically brazed for 15 s was 89.3 MPa, which was approximately 2.5 times higher than that brazed for 2 s, and the tensile failure mainly occurred at the interface between the Al_4.2Cu_3.2Zn_0.7 layer and the Cu-based diffusion layer.