A New Technique for Brazing Porous Copper to Copper Substrate Using CuNiSnP Amorphous Filler Metal

Furnace brazing is a common method for bonding porous metal to a substrate. However, it typically involves lengthy brazing times. This research introduces a novel rapid brazing technique to join porous copper to copper substrates. Using CuNiSnP amorphous filler metal, porous copper specimens were brazed under varying currents (250-1000 A) and times (900-1100 ms). Results showed successful joining without macroscopic deformation of the porous copper, and the brazing times were significantly shorter than those of traditional methods. Microstructural analysis revealed primary alpha, primary beta, and eutectic structures in the joint, all of which were influenced by brazing current and time. Adjusting the brazing conditions altered the morphology of the primary alpha structure, ranging from equiaxed to columnar dendrites, which in turn affected the joint's mechanical properties. The proposed technique offers an efficient method to manipulate joint microstructures for bonding porous copper to copper substrates, potentially improving manufacturing efficiency in industries such as heat exchangers or catalytic converters.