Discussion on the Failure of Vacuum Brazing Welds of Aluminum Alloy

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Discussion on the Failure of Vacuum Brazing Welds of Aluminum Alloy

The failure of aluminum alloy vacuum brazing weld is a key issue affecting the reliability of welding structure. Its failure mode involves multi-dimensional coupling effects such as material properties, process parameters, structural design and environmental factors. The following is a discussion on the failure causes and improvement measures:

Main reasons:

‌Oxide film is difficult to remove: A layer of refractory oxide film (mainly aluminum oxide) is easily formed on the surface of aluminum alloy, with a melting point of up to 2050 degrees, which makes it extremely difficult to remove this oxide film, thus affecting the welding quality.

‌High thermal conductivity: The thermal conductivity of aluminum alloy is about 2 to 4 times that of steel, which makes the heat dissipated quickly during welding, making it difficult to reach the ideal welding temperature, affecting the quality of the weld.

‌Large expansion coefficient: The expansion coefficient of aluminum alloy is large, which is easy to cause welding deformation and cracks, especially in aluminum alloy welding of thin plates.

‌Porosity problem: Porosity problems often occur during the welding of aluminum alloys. The hydrogen in the molten pool cannot be completely discharged before the weld is formed, leaving pores in the weld, affecting the strength and sealing of the weld.

‌Burn-through: Due to the low melting point of aluminum alloy, burn-through is prone to occur during welding, resulting in a decrease in weld quality.

‌Improvement measures‌:

‌Remove oxide film‌: Use mechanical or chemical methods to remove oxides from the groove of the workpiece and the surrounding parts and the surface of the welding wire before welding to ensure the cleanliness of the welding surface‌.

‌Use shielding gas‌: Use qualified shielding gas for protection during welding to prevent re-oxidation during welding‌.

‌Control heat input‌: Appropriately reduce welding current and arc voltage, increase welding speed to reduce heat input, prevent burn-through and pores‌.

‌Reasonably design groove‌: Large blunt edge size, reduce root gap, and reasonably design groove shape to reduce welding deformation and pores‌.

‌Preheat parent material‌: Preheat the parent material before welding to reduce the temperature gradient during welding and prevent cracks‌.

‌Select suitable welding wire‌: Select welding wire with the same or similar composition as the parent material to obtain better corrosion resistance and mechanical properties‌.

Optimize welding parameters: Improve the quality and stability of the weld by optimizing welding parameters such as welding current, arc length, welding speed, etc.

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Discussion on the Failure of Vacuum Brazing Welds of Aluminum Alloy

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