Brazing 55 vol.% SiC_p/ZL102 composites with Al-17.0Cu-8.0 Mg-1.5Ni filler metal

High-volume-fraction aluminum matrix composites reinforced with SiC particles (SiCp/Al MMCs) have been widely used in aerospace and other fields due to their excellent properties. However, joining high-volume-fraction SiCp/Al MMCs is challenging. In this work, an efficient and high-strength method was developed to join high-volume fraction SiCp/Al MMCs. SiCp/ZL102 composites (55 vol.%) were brazed by Al-17.0Cu-8.0 Mg-1.5Ni filler metal in atmospheric environment. Compared to as-cast filler metal, the foil-like filler metal prepared by melt-spinning has finer grains and superior diffusion performance. The microstructure, shear strength, and fracture morphology of the joint were investigated. The brazed joint at 580 degrees C for 30 min exhibited a maximum shear strength of 92 +/- 2 MPa, and the foil-like filler metal had optimal bonding performance with the base material. Meanwhile, the elements between the filler metal and base material interdiffused and metallurgical reacted. As a result, the oxide films on the surface of filler metal and of SiCp/ZL102 composites were broken; furthermore, Al2MgO4 and MgO were formed in the joint interface based on the redox reaction. The fracture type of brazed joint was a mixed ductile-brittle fracture.