Technical Information by Leszek Orman, Hans-Walter Swidersky and Daniel Lauzon

Abstract

For just as long as aluminium has been used for brazing heat exchangers, there has been a trend to down-gauging components for weight savings. The most common alloying element to achieve higher strength alloys for the purpose of down-gauging is magnesium. While magnesium additions are helpful in achieving stronger alloys, the consequence is a decrease in brazeability. This article discusses the mechanism of brazing deterioration with the addition of magnesium and proposes the use of caesium compounds as a way of combating these effects.

We split the article in five parts:

1. Introduction
2. Effects of Mg on the Brazing Process
3. Mechanism of Magnesium Interaction with the Brazing Process
4. Caesium Fluoroaluminates
5. NOCOLOK^® Cs Flux

Introduction

Aluminium brazing using non-corrosive fluxes is the leading process for manufacturing automotive heat exchangers. Recently, this process has become more wide spread in the stationary Heating, Ventilation, Air-Conditioning and Refrigeration (HVAC&R) industry, both for domestic and commercial applications. The standard brazing process involves joining of components with a brazing alloy, typically an aluminium-silicon filler alloy. Al-Si brazing alloys have melting ranges from 577°C to 610°C, which is appreciably lower than the melting point range of the base aluminium alloys used for heat exchangers (630°C – 660°C). Fluoride-based non-corrosive fluxes of the system KF-AlF₃ are used to displace the surface oxide film during the brazing process. A commonly used non-corrosive flux of the general formula K_1-3AlF_4-6 is known under the trademark name NOCOLOK® Flux with a melting range between 565°C and 572°C. The flux works by melting and disrupting the oxide film on aluminium, protecting the surfaces from re-oxidizing during brazing thus allowing the Al-Si brazing alloy to flow freely.

A consistent and on-going trend across all heat exchanger manufacturing sectors is towards lighter weight, accomplished by down-gauging of components. Also corrosion resistance is a key factor – particularly when there is no additional post brazing coating or treatment. These often contradictory trends call for aluminium alloys having higher and higher post brazed strength. While alloys from the 7xxx (alloyed with Zn) and 2xxx (alloyed with Cu) series can be precipitation hardened to the highest strengths of any aluminium alloys, their corrosion resistance without any additional coating is low and their solidus temperatures are below the melting range of currently used flux and filler metal combinations, and therefore they are not suitable for heat exchanger manufacturing by brazing.

The most common alloys used for aluminium brazing are from the 3xxx series (alloyed with Mn). After being subjected to the high temperature during the brazing cycle, these alloys have relatively low post-braze mechanical strength. Higher strength is offered by alloys from the 5xxx series (alloyed with 2 to 5 wt% Mg) where post brazed strengthening is achieved by solid solution hardening or by the 6xxx series (alloyed with Mg and Si) which can be precipitation hardened. A more comprehensive survey of mechanical properties of brazeable aluminium alloys is presented in [1]. It is worth observing that the brazing cycle itself could be considered as a thermal treatment for obtaining the precipitation hardening effect providing the cooling rate from the brazing temperature is sufficiently fast [2]. An example of such an alloy designated for specific use for aluminium brazed heat exchangers is described in detail in [3].

As well as increasing post-braze mechanical strength, the addition of Mg to certain alloys allows for improved machinability. Machining is necessary for heat exchanger components such as connecting blocks and threaded fittings.

There is however a certain limitation with the above mentioned alloys. They all contain magnesium. During the brazing cycle Mg negatively influences the process of oxide removal and it is generally accepted that Mg levels only up to 0.3% can be safely brazed with the standard brazing flux. This negative influence can be mitigated with the use of caesium containing compounds. The mechanism of Mg interference with the brazing process and the positive role of Cs additions to the flux in combating the effects of Mg are the subjects of the current paper.

To be continued soon…

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References:

1. S. W. Haller, “A new Generation of Heat Exchanger Materials and Products”, 6th International Congress “Aluminum Brazing” Düsseldorf, Germany 2010
2. R. Woods, “CAB Brazing Metallurgy”, 12th Annual International Invitational Aluminum Brazing Seminar, AFC Holcroft, NOVI, Michigan U.S.A. 2007
3. T. Stenqvist, K. Lewin, R. Woods “A New Heat-treatable Fin Alloy for Use with Cs-bearing CAB flux” 7th Annual International Invitational Aluminum Brazing Seminar, AFC Holcroft, NOVI, Michigan U.S.A. 2002
4. R. K. Bolingbroke, A. Gray, D. Lauzon, “Optimisation of Nocolok Brazing Conditions for Higher Strength Brazing Sheet”, SAE Technical Paper 971861, 1997
5. M. Yamaguchi, H. Kawase and H. Koyama, ‘‘Brazeability of Al-Mg Alloys in Non Corrosive Flux Brazing’’, Furukawa review, No. 12, p. 139 – 144 (1993).
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8. U. Seseke-Koyro ‘‘New Developments in Non-corrosive Fluxes for Innovative Brazing’’, First International Congress Aluminium Brazing, Düsseldorf, Germany, 2000
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11. K. Suzuki, F. Miura, F. Shimizu; United States Patent; Patent Number: 4,670,067; Date of Patent: Jun. 2, 1987
12. J. Garcia, C. Massoulier, and P. Faille, „Brazeability of Aluminum Alloys Containing Magnesium by CAB Process Using Cesium Flux,“ SAE Technical Paper 2001-01-1763, 2001