Challenges in flux-free laser beam brazing of aluminum
DVS Berichte, Band: 399 - Brazing, High Temperature Brazing and Diffusion Bonding (LÖT)
399
130-136
2025
Type: Zeitschriftenaufsatz (non-reviewed)
Abstract
Aluminum, known for its excellent lightweight properties, is widely used in aerospace and automotive industries.
Laser beam brazing is a common joining method, where flux is typically used to remove oxide layers.
Due to health and environmental concerns, research is being conducted with the aim of developing flux-free alternatives.
One approach involves the removal of oxides from aluminum sheets using nanosecond-pulsed laser radiation.
To prevent reoxidation, an oxygen-free atmosphere is employed by adding monosilane to the process gas,
reducing the oxygen partial pressure to as low as 10-18 mbar. The laser beam brazing process is then carried
out in the oxygen-free atmosphere after the oxide removal.
This study investigates the laser beam brazing of EN AW-6082 aluminum sheets with AlSi-12 filler wire, in
configurations like bead-on-plate, butt, and lap joints. Comparisons between flux and flux-free brazing show
challenges in the latter, particularly the significant impact of the oxide layer on the filler wire on wetting, as conventional continuous wave brazing does not sufficiently disrupt these oxides. To further improve wetting, a hybrid cw and pulsed wave process is proposed. The introduction of laser pulses alongside the cw spot creates more turbulence in the molten filler wire. Preliminary results from bead-on-plate seams show enhanced wetting of the filler wire and less melting of the base material.