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Brazing Alloys
Filler metals based on nickel-palladium
filler metals in critical superalloy
replace
gold-based
brazements
Introduction
Aircraft engine fabricators have traditionally used brazing processes for joining
engine components. Nickel- and goldbased filler metals are primarily used in
these applications due to their superior
performance at elevated temperatures.
Historically, one gold-based alloy, designated by the American Welding Society
as BAu-4, has established itself as a
dependable filler metal to many fabricators. Although this filler metal is finding
less use due to its precious metal content,
many critical engine components, especially those made of 7 ' hardened superalloys, are still brazed with BAu-4. The 7 '
hardened superalloys (such as Inconel718*) should not be brazed at temperatures exceeding 1010C (1850F), to prevent possible coarsening and dissolution
of strengthening phases ( 7 ' or 7"), as
well as to inhibit grain growth during
brazing operations. The brazing temperature of BAu-4 is below 1010C (1850F),
and it provides necessary elevated temperature properties. Furthermore, the
availability of BAu-4 in flexible foil forms
makes it suitable for joining parts of
complex shapes.
Prior studies (Refs. 1-3) have indicated
that a number of nickel-based filler metals
of the AWS BNi family, which are currently available as flexible metallic glass foil
form, also provide adequate elevated
temperature properties in certain base
metals. However, the brazing temperatures of such alloys are higher than
1010C (1850F), making these alloys
unsuitable for joining 7 ' hardened superalloys.
Recently, it has been demonstrated
that alloys of the Ni-Pd-Cr-Fe-B-Si family
containing up to 36 wt% Pd possess
solidus and liquidus temperatures comparable to those of BAu-4 (Ref. 4). Hence,
the brazing temperature for these compositions are also below
1010C
(1850F), making them suitable for use as
filler metals for joining 7 ' hardened
superalloys. It has also been realized that
these alloys can be processed into flexible metallic glass foil form by rapid solidification techniques.
The present study has been structured
to investigate the fundamental characteristics of Ni-Pd filler metals in brazing. The
mechanical properties, corrosion behavior and microstructural characteristics of
joints prepared with these filler metals
are compared to BAu-4 brazed joints.
Recommendations on optimum alloy
composition are derived.
Alloy Development
Based on a paper presented at the 14th
The objective of alloy development
International A WS-WRC Brazing and Soldering
efforts was to produce a filler metal alloy
Conference held in Philadelphia, Pa., April
according to the following criteria:
26-28, 1983.
1. Adequate flowability at or below
1010C (1850F).
D. BOSE, A. RABINKIN and N j. DE CRISTOFA2. Glass forming composition to proRO are with Allied Corp., Metglas Products.
vide flexible and preformable ribParsippany, N. j. A. DATTA is with EG&G
bon.
Sealol, Inc., Providence, R. I.
3. Precious metal content lower than
BAu-4.
"Trademark of International Nickel Company,
4. Joint mechanical properties compaN.Y.
By the elimination of silicon, the f o r m a t i o n of hard and brittle silicides in the joint
is a v o i d e d . F u r t h e r m o r e , alloys containing
b o t h b o r o n a n d silicon w e r e characterized by a w i d e melting range w i t h l o w
solidus t e m p e r a t u r e s , m a k i n g t h e m less
suitable f o r high t e m p e r a t u r e applications.
Experimental Procedures
MBF-1001X< >
MBF-1002X<a>
MBF-1003X<a>
BAu-4<b>
(a)
Ni
Pd
Bal
Bal
Bal
35.32
32.25
27.12
Cr
Fe
63
61
83
4.63
0.93
0.95
Au
2.69
2.69
1.84
2.38
82.0
(b)
Material Specifications
T h r e e Ni-Pd alloys a n d BAu-4 w e r e
selected f o r detailed joint characterizat i o n . T h e nominal chemical c o m p o s i t i o n s
of brazing filler metals are given in Table
1. Alloys MBF-1001X a n d MBF-1002X
contain Ni, Pd, Cr, Fe a n d B. By c o m p a r i s o n , alloy MBF-1003X contains silicon, in
a d d i t i o n t o t h e a b o v e - m e n t i o n e d elements. T h e liquidus and solidus t e m p e r a tures of the filler metals w e r e d e t e r m i n e d
b y D T A t e c h n i q u e and are listed in Table
2.
T h e n o m i n a l chemical c o m p o s i t i o n s o f
the base metals lnconel-718 a n d AISI-316
stainless steel are given in Table 3.
Lap Shear Tests
Figures 1 a n d 2 s h o w t h e dimensions o f
single lap shear samples m a d e w i t h l n c o n el-718 and AISI-316 base metals, respectively. Prior t o brazing, t h e mating surfaces of the blanks w e r e r o u g h e n e d b y
using N o . 8 0 grit e m e r y paper, f o l l o w e d
b y ultrasonic degreasing in a c e t o n e a n d
rinsing in a l c o h o l . All filler metal foils w e r e
0.338 m m (0.0015 in.) thick and served as
joint spacers. A f t e r fixturing, the edges of
the samples w e r e lightly tack w e l d e d b y
gas tungsten arc w e l d i n g t o h o l d t h e
assemblies t o g e t h e r d u r i n g brazing.
Brazing w a s p e r f o r m e d in a v a c u u m
furnace at a v a c u u m o f a b o u t 10 - " 1 t o
10~ 5 torr. A f t e r brazing, the lnconel-718
samples w e r e solution t r e a t e d in t h e
f o l l o w i n g m a n n e r t o achieve o p t i m u m
strength of t h e base m e t a l : 9 8 0 C
( 1 8 0 0 F ) / 1 hr, air c o o l t o r o o m t e m p e r a t u r e , 7 2 0 C ( 1 3 2 5 F ) / 8 hr, f u r n a c e c o o l
t o 6 2 0 C ( 1 1 5 0 F ) / 8 hr, a n d finally, air
Ductility Tests
Corrosion Test
C o r r o s i o n properties of MBF-1002X
and lnconel-718 w e r e e x a m i n e d at r o o m
t e m p e r a t u r e in 0.1 N K O H solutions w i t h
and w i t h o u t 0.1 N KCI. Since glassy filler
metal foils devitrify d u r i n g brazing (Ref.
7), the MBF-1002X foil w a s h e a t e d t o a
t e m p e r a t u r e b e l o w its solidus t o transf o r m its structure f r o m a m o r p h o u s t o
crystalline. Strips o f these alloys w e r e
e x a m i n e d in an electrochemical cell,
w h e r e they served as the test electrodes.
Platinum foil in the cell w a s used as the
c o u n t e r e l e c t r o d e . Potentials of the test
electrodes w e r e d e t e r m i n e d w i t h respect
t o a saturated calomel e l e c t r o d e (SCE)
situated in a separate c o m p a r t m e n t ,
a t t a c h e d by a liquid j u n c t i o n t o the cell.
Designation
MBF-1001X
MBF-1002X
MBF-1003X
BAu-4
Liquidus
Temperature,
C(F)
Solidus
Temperature,
C (F)
Brazing
Temperature,
C (F)
996
(1825)
993
(1819)
985
(1805)
970
(1778)
945
(1733)
934
(1713)
825
(1517)
946
(1735)
1010
(1850)
1010
(1850)
1010
(1850)
1004
(1840)
Brazed
were
cross-sec-
specimens
Ni
12.0
Ni4- Co = 52.5
Cr
Fe
Mo
Si
Others
17.0
19.0
Bal
18.5
2.5
3.0
1.0
Mn2.0
Cb -I- Ti = 5.1
I-
5.715 c m (2.25")
Mechanical Properties
y-
0-
11
u.
'
7^
2.667 cm
(1.050")
R 0.953 cm (0.375")
1.27 cm (0.5")
_J
**
X
0.158 cm (0.0625")
c
a
IL
IT,
U.
12.7 cm (5.0")
^r
11
-0-
>
1.27 c m (0.5")
2.858 cm
(1.125")
>
, L
~~f
"C
CE
-^
IZ
u.
D.
R 1.27 c m (0.5")
u
C
0.318 c m (0.125")
"aa.
I
a
cc
<i
Ul
V.
I-
Z
u
5
Q.
o
_l
Tests
LU
E
a
C
_
u.
>
u
c
>
LU
tx
<
UJ
y.
5.715 cm (2.25")
L
\ 1
"V
\_J
'y
I
I I I
1.27 cm (0.5")
Strength
a
i
c
>-
dI>)
2.667 cm
(1.050")
R 0.953 cm i 0.375")
-J
LU
>
LU
i
Filler Metal F o i r
E
a
0 . 1 5 8 c m (0.0625")
a
ac
<
LU
WJ
LU
Overlap Distance
[t = 0.159 cm
(0.063 in.)]
Shear Strength
MPa (psi)
2t
4t
2t
4t
2t
4t
2t
4t
337 (48,813)
222 (32,187)
376 (54,560)
240 (34,820)
354(51,280)
249 (36,160)
270 (39,200)
221 (32,080)
Tensile Strength
MPa (psi)
687
887
752
946
700
997
540
885
(99,627)
(128,747)
(109,120)
(137,280)
(102,600)
(144,640)
(78,400)
(128,320)
MBF-1001X
Comments
Failed
Failed
Failed
Failed
Failed
Failed
Failed
Failed
in
in
in
in
in
in
in
in
joint
joint
base
base
joint
base
joint
base
MBF-1002X
metal
metal
MBF-1003X
metal
BAu-4
metal
tr
~~
Brazement
Characteristics
Did not
develop
cracks
Did not
develop
cracks
Did not
develop
cracks
Developed
cracks
h-
Comments
Ductile
joint
Ductile
joint
UJ
E
a
>
UJ
Ductile
joint
oitr
Brittle joint
UJ
<
v>
ui
tr
Alloy
MBF-1001X
MBF-1002X
MBF-1003X
BAu-4
Time of Failure
@ 455 kg (1000 Ib)
Did not fail after 300 hr
Did not fail after 300 hr
Did not fail after 300 hr
I hr
Alloy
MBF-100IX
MBF-1002X
MBF-1003X
BAu-4
Time of Failure
228 kg
455 kg
(@500 Ib)
(@1000 Ib)
60 min
138 min
0.0 min
0.0 min
6.0
12.0
0.0
0.0
min
min
min
min
,y945
v996
MBF-1001X
^976
MBF-1002X
Structure-Property Correlation
Based on DTA and mechanical properties, addition of silicon to Ni-Pd-Cr-B leads
to detrimental effects. The silicon-andboron-containing MBF-1003X has a wider
melting range and is characterized by a
lower solidus compared to the boroncontaining MBF-1001X and 1002X. Also,
mechanical properties of MBF-1003X
brazements are comparatively inferior to
those of MBF-1001X and MBF-1002X.
These phenomena are believed to stem
from palladium silicide formation in joints
brazed with MBF-1003X. Therefore, it
behooves us to examine representative
brazed joint microstructures and determine the role of silicon in modifying joint
morphology and associated mechanical
properties. For this comparison, brazed
joints were made using AISI-316 stainless
steel base metal. Filler metals used were
MBF-1001X and MBF-1003X alloys. Brazing was performed in a vacuum furnace
at a vacuum of about 1 0 - 4 torr for 10 min
Temperature (C)-
Fig. 5 Thermograms of various alloys
Cr and B.
"W..
4A
*[Cr,B)
GNi.Pcn
.
K '-**
Fig. 6 - Photomicrographs of AISl-316/MBF-100IX joint brazed for 10 min. A portion of the narrow centerline eutectic in A (inside the black box) is
shown at a higher magnification in B
-alO a
* * "
i
CCr.B)
#;
400
500
600
700
900
ai
- af" |
"'
-ft
jm -
1000
'**
1,
' -
ccr.e)
Kinetic Energy, Ev
Fig. 7 Differentiated spectrums of Auger electrons obtained from different phases of AISI316/MBF-1001X joint brazed for 10 min
Q.
ui
>
ui
o
o
tr
<
Ul
tn
o
tr
<
LU
(/>
UJ
tr
ui
E
CL
O
i
ui
>
X
o
tr
<
UJ
t/>
UJ
tr
II
.2
"c
(0
01
*o
>.
UJ
vi
&8
S3
+*
3 'S
o
a.
e
o
'5
o
>
"5
o
o
c
o
1-
1
E
o
_o.-
Q)
o
a.
Anodic C o m p o n e n t Of lnco-718
/ ( D i s s o l u t i o n & Oxide Formation)
i 1
.2
o 17
-w^.
1 *
X
^^-zz>*-^"\Anodic
C o m p o n e n t of MBF-1002X
r^*^
(Dissolution & Oxide Formation)
Cathodic C o m p o n e n t of MBF-1002X
x M 0 , - l - 2 H ; , 0 + 4e = 4 O H ~ )
^^^^"i
X
**
U
v ^
^ v *
UJ 1
C a t h o d i c C o m p o n e n t Of lnco-718
/ ( 0 2 + 2 H 2 0 + 4e = 4 O H " )
10
^ " S a
10
Current Density (Amp/cm2)
10
Fig. 12 - Corrosion beha vior of MBF- 1002X brazing alloy and lnconel-718 base metal in chlorina ted
0. IN KOH solution
a-
uT +
8m
tn
>
X
a ^ ~ X _
'
a.
c
2
u
o
Uj
to __
i i
3 45678
10"
10"
10"
X
10 " 4
Conclusions
Nickel-palladium based filler metals in a
flexible metallic glass foil f o r m h a v e b e e n
d e v e l o p e d primarily as replacements f o r
gold-based filler metals, such as A W S
BAu-4 (82Au-18Ni w t % ) . Like BAu-4, the
brazing t e m p e r a t u r e s of the Ni-Pd alloys
are b e l o w 1 0 1 0 C (1850F), r e n d e r i n g
t h e m suitable f o r joining critical aircraft
engine c o m p o n e n t s m a d e w i t h 7 ' hard-
Acknowledgments
ooo
References
1. Schaeffer, R.P., Flynn, I.E., and Doyle, J.R,
1971. Brazing filler metal evaluation for an
aircraft gas turbine engine application. Welding /ournal 50 (9):394-s to 400-s.
2. Eng, R.D., Ryan, E.J., and Doyle, J.R.
1977. Nickel-base brazing filler metals for aircraft gas turbines. Welding journal 56 (10):1521.
3. Bose, D., Datta, A., and DeCristofaro, N.
1981. Comparison of gold-nickel with nickel
base metallic glass brazing foils. Welding /ourna/60(10):29-34.
4. D'Silva, T.L. 1979. Nickel-palladium base
brazing filler metal. Welding journal 58
(10):283-s to 286-s.
5. Omori, S., Hashimoto, Y., Shoji, K., Hidaka, K and Kohira, Y. 1972. Liquidus surfaces
of ternary nickel-boron-silicon alloy for infiltrant. Powder and Powder Metallurgy (Japan)
(Funtai Oyobi Funmatsuyakin) 18:22-26.
6. Hansen, M. 1958. Constitution of Binary
Alloys. McGraw Hill, New York, N.Y.
7. DeCristofaro, N and Henschel, C. 1978.
METGLAS brazing foils. Welding Journal 57
(7):33-38.
8. Bockins J., and Reddy, A. 1970. Modern
Electrochemistry. Vol. 2, Plenum Press, New
York, N.Y.