Este estudo avaliou a precisão de duas técnicas de união, a brasagem e a soldagem a laser, em estruturas metálicas de uma prótese clássica de Brånemark. Dez estruturas fundidas em NiCr foram segmentadas em 4 partes e analisadas no MEV em pontos pré-estabelecidos, vestibular e proximal, totalizando 8 pontos de análise para cada estrutura. Na primeira fase, foi mensurada a fenda marginal existente entre o análogo do implante e o abutment UCLA antes da união destes segmentos através da brasagem e da soldagem a laser. Após esta análise inicial, as 10 estruturas foram divididas aleatoriamente em dois grupos. O grupo que seria unido pelo processo da brasagem, utilizando maçarico gás/oxigênio, apresentou uma fenda marginal média de 5,94µm, já o grupo que seria unido através da soldagem a laser, uma fenda marginal média de 7,22µm. Os segmentos de cada estrutura metálica foram parafusados com 10Ncm aos respectivos análogos da plataforma de trabalho e unidos com resina acrílica Pattern Resin LS (GC America Inc, USA). Após a polimerização da resina, a estrutura foi desparafusada e submetida ao processo da brasagem ou da soldagem a laser e analisada no MEV nas mesmas posições pré-estabelecidas antes da união. Esta análise foi realizada na mesma plataforma de trabalho. Para tal, os quatro parafusos de fixação foram rotacionados até que fosse detectada uma leve resistência. Neste momento, somente o parafuso de uma das extremidades recebeu um torque de 10Ncm e os demais parafusos foram soltos. A média das fendas marginais após o processo da brasagem passou a ser de 18,80µm e a média das fendas marginais após a soldagem a laser passou a ser de 12,38µm. A análise de covariância mostrou que a diferença das fendas depois e antes da união através da brasagem foi maior que a diferença das fendas obtidas através da soldagem a laser (p = 0,001). Apesar da brasagem apresentar uma distorção significativamente maior quando comparada à soldagem a laser, ambas mostraram valores de fenda marginal clinicamente aceitáveis. No entanto, ficou evidente a facilidade de execução da técnica a laser em relação à brasagem, principalmente no que tange ao tempo necessário para a realização de cada uma delas. / In this study we assess precision of two union techniques, brazing and laser welding, in metallic structures of a Brånemark classical prosthesis. Ten structures cast in NiCr were segmented in four parts and analyzed in the SEM in pre-established points, vestibular and proximal, in a total of 8 analysis points for each structure. In this first phase, we measured the marginal fissure between the implant analogous and the UCLA abutment before the union of these segments using brazing and laser welding. After this initial analysis, we randomly divided the ten structures in two groups. The group that would be united by the process of brazing, using gas/oxygen blowpipe, presented an average marginal fissure of 5,94µm and the group that would be united by laser welding, an average marginal fissure of 7,22µm. The segments of each metallic structure were screwed with 10Ncm to the respective analogous of the work platform and united with acrylic resin Pattern Resin LS (GC America Inc., USA). After polymerization of the resin, the structure was unscrewed and submitted to process of brazing or laser welding and analyzed in the SEM in the same positions pre-established before the union. This analysis was made in the same work platform. To do so we rotated the four fixation screws until we felt a light resistance. At this moment, only the screw of one of the edges received a torque of 10Ncm and the other screws were released. The average of the marginal fissures after the brazing process was 18,80 µm and the average of the marginal fissures after the laser welding process was 12,38µm. The analysis of the covariance showed that the difference of the fissures after and before the union using brazing was bigger than the difference of the fissures obtained with the laser welding (p = 0,001). Despite the fact that the brazing presents a distortion significantly bigger when compared to the laser welding, both techniques showed clinically acceptable values of marginal fissures. However, it is clear how easy the execution of the laser technique is in relation to the brazing, mainly in relation to the time that is needed for each technique.

A técnica de soldagem apresenta vantagem de união de partes metálicas que permite melhora na adaptação e uniformidade na distribuição das forças mastigatórias, minimizando falhas no tratamento reabilitador. O objetivo foi avaliar a resistência flexural entre três métodos de soldagem diferentes: Chama Direta a maçarico, método TIG - Tungstênio gás inerte (Soldadora NTY - Kernit, Brasil) e o método de solda a Laser (Soldadora Desktop - Dentaurum, Alemanha) comparando a um grupo controle (Monobloco). Os espécimes cilíndricos foram obtidos a partir de canais de cera pré-fabricados com 3mm de diâmetro e 30mm de comprimento, fundidos em liga de Ni-Cr e seccionados transversalmente, formando os grupos T1 e L1. Depois da secção, dez espécimes dos grupos L e T receberam chanfros em 45° para preenchimento, formando os grupos (L2 e T2). As extremidades foram unidas com resina acrílica obedecendo a uma distância pré-determinada, de 0,3mm para o grupo chama direta, 0,1mm para o grupo TIG e juntas do tipo topo a topo para o grupo laser. Os corpos foram incluídos e soldados de acordo com a proposição. Após a soldagem os corpos de prova foram torneados e levados ao teste de flexão. Os dados foram submetidos aos testes estatísticos (ANOVA e Student-Newman-Keuls - p <0,05) para comparações múltiplas. De acordo com os resultados (MPa) o grupo M (1796,55) obteve o maior valor, seguindo pelo grupo C(1370,56), ficando o grupo T1(990,84) com o valor menor. Não houve diferença estatística entre os grupos soldados, existindo somente diferença entre os grupos de teste para o grupo controle em monobloco. No entanto podemos afirmar que o preenchimento parece influenciar discretamente os resultados da resistência flexural no grupo TIG. Conclui-se que o método TIG produz resultado semelhante ao laser e a chama direta, o que é clínica e operacionalmente importante. / The welding technique presents advantage of union of metallic parts that improves the adaptation and appropriate distribution of the bite forces, minimizing flaws in the dental prostheses. The objective was to evaluate the flexural strength in different welding methods: Brazing; Laser (Welder Desktop - Dentaurum, Germany) and Tungsten inert gas - TIG (Welder NTY - Kernit, Brazil), comparing to a control group (non-welded). The cylindrical specimens were obtained from prefabricated wax conduits with 3mm of diameter and 30mm of length, melted in Ni-Cr alloys and split up transversally, forming the groups T1 and L1. After of the section the groups L and T received slices in 45° for fulfill, forming the groups (L2 and T2). The extremities were united with acrylic resin obeying a predetermined distance, from 0,3 mm to the brazing group, 0,1 mm to the TIG group, and in the laser group there wasn\' t any space between the extremities of jointing. The specimes were included and welding in agreement with the proposition, turned and conducted to the flexion test. The data were submitted to the statistical test (ANOVA and Student-Newman-Keuls - p<0,05) for multiple comparisons. According to the results (MPa) the control group (1796,55) obtained the largest average value, followed by the brazing group (1370,56), being the group T1(990,84) with the smallest value. In terms of statistics there was no difference between the groups with welding, existing only difference among the tested groups for the control group. However, we can affirm that the completion seems to influence the results of the resistance flexural discreetly in the TIG group. It can be concluded that the TIG method produces similar result to the laser and the brazing, what is clinical and important operationally.

Dans cette étude la céramique Ti2AlC a pu être brasée avec succès sur un substrat de Ni dans une gamme de température allant de 1000°C à 1100°C et pour des temps de maintien de 10 à 60 mn. Les mécanismes mis en œuvre pendant la brasure ont été mis en lumière en étudiant la microstructure du joint Ti2AlC/Ni. On montre ainsi que le nickel provenant du métal d’apport BNi-2 diffuse dans Ti2AlC, majoritairement le long des joints de grains et parfois aussi dans certains grains d’orientation favorable. Le phénomène d’interaction induit des variations de fluidité du métal d’apport liquide. En conséquence, l’épaisseur des joints réalisé sont fonction des différents paramètres de brasage. La résistance maximale au cisaillement est obtenue à 1100°C après un temps de maintien de 30 min. Dans un second temps, l’interaction entre les principaux éléments contenus dans le métal d’apport (c.-à-d. Ni, Cr et Si) et le substrat Ti2AlC a été expliqué à l’aide de modélisations DFT. Il est montré que ces trois éléments ont chacun leur site de substitution spécifique. Les atomes de Si se placent plutôt sur le site Al, le Cr sur le site Ti et les atomes de Si sur le site de l’aluminium. Deux voies de décomposition de Ti2AlC en présence de défauts ont également été identifiées soit en raison de modes de vibrations instables, soit en raison de la compétition avec d’autres phases. / In the present work, the brazing experiments of Ti2AlC ceramics to Ni substrate have been successfully performed in the temperature range between 1000°C and 1100°C, with the holding time varying from 15 min to 60 min. The corresponding mechanisms have been disclosed by studying the microstructure of the Ti2AlC/Ni joint. It is found that the Ni element originating from the BNi-2 filler can diffuse into the Ti2AlC substrate during the brazing process, mainly along the grain boundary, or in some grains with special orientations. The interaction process induces some differences in the fluidity of the liquid filler; consequently, the thickness of the Ti2AlC/Ni joints achieved finally is different at different brazing parameters. The maximum shear strength is measured to be 193 MPa, achieved at 1100°C holding for 30 min. Afterwards, the interaction behavior between the filler elements (including Ni, Cr and Si) and the Ti2AlC substrate, has been explained by DFT simulation. It is found that the three kinds of filler elements have their own preferred substitution sites: Ni atoms are most likely to be found at Al site, Cr atoms at Ti site, and Si atoms at Al site. Then, the decomposition mechanisms of the defective Ti2AlC model have been illustrated as well, which might occur in two possible means: unstable vibrational behaviors, and lower Gibbs energy of competing phases.

Gegenstand der Arbeit ist die Suche nach einer Technologie zum stoffschlüssigen Fügen von Leichtbaustrukturen, die aus Aluminiumblechen bestehen. Hohe Anforderungen an die Oberflächenqualität der Fügestelle können dabei nur durch den Einsatz eines Lötprozesses erfüllt werden. Es wird theoretisch untersucht, welche werkstoffspezifischen und technischen Schwierigkeiten das Hartlöten von Aluminium im allgemeinen hervorruft. Unter deren Berücksichtigung werden Lösungsansätze getroffen und bewertet. Im Ergebnis dieser Bewertung wird ein Hartlötprozeß modelliert, bei dem unter Verzicht auf Flußmittel ein Festkörperlaser als Wärmequelle dient. Zur Abschätzung der Vorgänge im Fügespalt, in der Oxidhaut an der Aluminumoberfläche sowie der Temperaturverläufe in den Fügeteilen erfolgen Simulationsrechnungen. Einer ersten experimentellen Überprüfung folgen Modifikationen des Prozesses und deren erneute Simulation. Technologische Versuche testen den Einsatz besonderer Lotwerkstoffe sowie eines zusätzlichen Aktivierungslasers. Metallographische Untersuchungen gelöteter Probebleche geben Aufschluß über den Stoffschluß, der trotz sehr kurzer, lötuntypischer Prozessdauer und ohne Anschmelzung des Grundwerkstoffs eintritt. Zum Abschluß wird in einigen grundlegenden Versuchen überprüft, inwiefern anhand der gewonnenen Erkenntnisse auch ohne den hohen technischen Aufwand des Hochleistungslasers ein flußmittelfreier Hartlötprozeß realisierbar ist.

The approach advocated in this work implements energy/exergy analysis and indirectly an irreversibility evaluation to a continuous manufacturing process involving discrete net shape production of compact heat exchangers through a complex controlled atmosphere brazing (CAB) process. The system under consideration involves fifteen cells of a continuous ramp-up heating, melting, reactive flow, isothermal dwell, and rapid quench solidification processing sequence during a controlled atmosphere brazing of aluminum compact heat exchangers. Detailed mass, energy, and exergy balances were performed. The irreversibility sources were identified and the quality of energy utilization at different processing steps determined. It is demonstrated that advanced thermodynamics metrics based on entropy generation may indicate the level of sustainable energy utilization of transient open systems, such as in manufacturing. This indicator may be related to particular property uniformity during materials processing. In such a case, the property uniformity would indicate systems distance from equilibrium, i.e., from the process sustainable energy utilization level. This idea is applied to net shape manufacturing process considered. A metric based on exergy destruction is devised to relate the heat exchanger temperature uniformity and the quality. The idea advocated in this thesis will represent the coherent framework for developing energy efficient, economically affordable and environmentally friendly manufacturing technology.

The objective of this thesis is to study the effects of flux deposition non uniformity on spreading of molten metal. Flux deposition non-uniformity here means as to whether the amount of flux deposited in a non-uniform or uniform pattern helps in the better wetting and spreading characteristics of the molten metal or is detrimental to the process. The material selection constraint to the study was imposed by selecting brazing of aluminum i.e., aluminum alloy melting and flow over an aluminum alloy substrate. The study was carried out by conducting a number of Hot Stage microscopy tests using aluminum silicon alloy as the filler metal and Potassium Fluoro Aluminate (Nocolok) as the flux. The flux was applied in different spatial distribution patterns to uncover the varying effects of its distribution on spreading. The uneven pattern of flux deposition indicates the influence on spreading but due to the efficient spreading of flux prior to aluminum melting and associated fuzziness of the achieved coverage distribution the effects are not always conclusive. It has been concluded that non uniform flux deposition does not necessarily mean uneven or less uniform spreading of the molten liquid metal if the spreading of the molten flux is beyond the distance of ultimate metal spreading. This is because, in spite of uneven flux deposition, the flux melts approximately at 560C-570C and spreads on the surface of the metal thereby promoting appreciable spreading and wetting of the molten liquid metal that happens at temperatures above 577C.

This work involves investigation of the kinetics data of a joint formation during aluminum alloy brazing. Data was generated by several groups of experiments conducted under conditions of a controlled oxygen level of the background brazing atmosphere. Generated data are examined to identify the phases of the joint formation and the time frame of its evolution. Specifically, the triple line kinetics data are analyzed to verify whether a power law between (1) the triple line of the molten metal preceding joint formation and (2) the formation time can be established for each formation phase. In addition, both initial and residual clad thicknesses on brazing sheets are studied to check phenomenologically an impact of silicon diffusion on joint formation. Formation shapes are also inspected in order to study if a 2-D configuration of joint formation is present. The kinetics data from different sets of experiments under adverse atmosphere conditions are compared to understand the impact of oxygen level on joint formation. This study is not necessarily aimed at building a mathematical model for T-Joint formation during brazing process, but intends to understand possible influential parameters on the development of the formation. KEYWORDS: Aluminum Brazing, Kinetics, T-Joint, Background Atmosphere, Capillary Flow.

Sustainable manufacturing involves utilizing energy resources efficiently. Currently, the state of sustainability for a given manufacturing process is described by most in a qualitative sense as opposed to using quantitative metrics. This thesis offers a segment of analysis needed to understand the state of sustainability in the context of energy resource utilization. This was accomplished by measuring the order of magnitude difference between the energy consumption of a manufacturing process vs. the theoretical minimum amount of energy required to complete the same task (aluminum T-joint bond). This analysis was completed for a TIG welding process and a controlled atmosphere brazing (CAB) process. Also, the energy Sankey diagram was constructed for the TIG welding process. The TIG welding process and CAB process consumed an average of 136.1 ± 16.5 kJ and 6,830 ± 77 kJ respectively to bond the same sample. The TIG welding process consumed O(102 kJ) more than the theoretical minimum amount needed to complete the same bond while the CAB process consumed O(104 kJ) more than the theoretical minimum. In the context of energy consumption, there are sizable margins for improvement for both metal joining processes analyzed in this study.

The ability to effectively join magnesium alloys to steel will facilitate increased application and use of Mg alloys in the automotive and aerospace industries where joining Mg alloys to steel in order to achieve light weight, versatile and tailored properties in one composite part is highly desirable. The current thesis details (i) the development of a laser brazing technology for joining Mg alloy-interlayer-steel dissimilar metal combinations, (ii) thermochemical analysis of phases formed at the interface of a Mg alloy-steel joint during laser brazing, (iii) the bonding mechanisms in the Mg alloy-interlayer-steel joints using Al-12Si, Ni, and Sn interlayers, and (iv) the mechanism responsible for wetting of steel by molten Mg alloy during the laser brazing. Firstly, a diode laser brazing procedure has been developed for joining AZ31B-H24 Mg alloy sheet to aluminum coated steel sheet using a AZ92 Mg alloy filler wire. The results of this study suggest that feasibility of this process depends strongly on the pre-existing Al-12Si coating layer on the steel sheet that promotes wetting of the AZ92 Mg alloy filler alloy as well as formation of a layer of θ-Fe(Al,Si)3 interetallic compound along the fusion zone-steel interface. The average joint efficiency was 29% with respect to the AZ31B-H24 Mg alloy base metal. Failure occurred when cracks propagated along the intermetallic layer. Secondly, to predict early stage phase formation in the Mg alloy-interlayer-steel system during the laser brazing process, the thermodynamic stability of precipitated phases at the Mg alloy-Ni-steel interface during laser brazing has been evaluated using FactSage thermochemical software. Assuming local chemical equilibrium at the interface, the chemical activity-temperature-composition relationships of intermetallic compounds that might form in the AZ92 magnesium alloy-Ni-steel system in the temperature range of 600-1100 °C were estimated. The addition of a Ni interlayer between the steel and the Mg brazing alloy was predicted to result in the formation of the AlNi, Mg2Ni, and Al3Ni2 intermetallic compounds at the interface depending on the local maximum temperature. This was confirmed experimentally by laser brazing of AZ31B-H24 magnesium alloy and steel sheet with a micro-layer of electro-deposited Ni using AZ92 magnesium alloy filler wire. Bonding between the magnesium alloy and the steel was facilitated by the formation of a transition layer composed of a solid solution of Ni in Fe on the steel followed by a layer of α-Mg + Mg2Ni eutectic. A band of AlNi with different morphologies also formed along the fusion zone-steel interface, but was not directly responsible for bonding. The average joint efficiency was 56.5% with respect to the AZ31B-H24 Mg alloy base metal and 94.8% higher than that of laser brazed joint using Al-12Si interlayer. Thirdly, to study a low melting point temperature interlayer element, the brazeability of AZ31B-H24 magnesium alloy sheet to Sn-coated steel sheet has been investigated. All tensile-shear specimens fractured in the steel base metal well away from the brazed joint. The results showed that while the Sn coating promoted good wetting between the molten filler alloy and the steel sheet, it did not play a role in forming the final bond. Its primary function appeared to be in maintaining a clean, oxide-free steel surface until the molten Mg filler alloy could come in direct contact with the steel surface. Bonding between the magnesium alloy and the steel was facilitated by the formation of two nano-scale transition layers composed of Fe(Al) solid solution on the steel followed by a layer of Al8Mn5 phase on top of Fe(Al) in the fusion zone along the interface. High resolution-TEM analysis showed that an orientation relationships (OR) with low angle of rotation of the matching planes and low interplanar mismatch existed at the Fe(Al)-Al8(Mn,Fe)5 interface. This was found to be responsible for the low interfacial energy density, good wetting and strong interfacial bond observed in this complex dissimilar metal system. Finally, wetting has been characterized by measuring the contact angles of AZ92 Mg alloy on Ni electro-plated steel as a function of measured peak temperature reached during laser heating. Reactions between molten Mg and Ni led to a contact angle of about 86º in the peak temperature range of 618-750 ºC (denoted as Mode I) and a dramatic decrease to about 46º in the temperature range of 824-1020 ºC (denoted as Mode II). Scanning and transmission electron microscopy (SEM and TEM) indicated that AlNi + Mg2Ni reaction products were produced between Mg and steel (Mg-AlNi-Mg2Ni-Ni-Fe) in Mode I, and just AlNi between Mg and steel (Mg-AlNi-Fe) in Mode II. From high resolution TEM analysis, the measured interplanar mismatches for different formed interfaces in Modes I and II were 17% {Mg-AlNi}-104% {AlNi-Mg2Ni}-114% {Mg2Ni-Ni} and 18% {Mg-AlNi}-5% {AlNi-Fe}, respectively. Therefore, it is suggested that the poor wettability in Mode I was caused by the existence of Mg2Ni since AlNi was the immediate layer contacting molten Mg in both Modes I and II and the presence of Mg2Ni increases the interfacial strain energy of the system. This study has clearly demonstrated that the lattice mismatching at the interfaces between reaction product(s) and substrate, which are not in direct contact with the liquid, can greatly influence the wetting of the liquid.

In this study, a cold worked tool steel and a low carbon steel ( St 37 ), which were joined by brazing, were subjected to impact and shear loading. The end product is used as paper cutting blades in the industry. Effects of different brazing filler metals on the delamination of the blades under impact loading and on the impact toughness of the blades were studied. The target is to achieve higher impact toughness values without delamination. Impact toughness of the steels, joined by Cu, CuNi and BNi brazing filler metals and separation of brazed surfaces under shear loading were studied. The microstructures that were formed as a result of each application were studied by scanning electron microscopy and x-ray diffraction. The results indicate that brittle intermetallic compounds are formed in BNi brazing filler metal application. It is observed that CuNi alloy with 24% wt Ni form stronger bonds with the base metals than pure Cu and 10% wt Ni CuNi alloy.