Development of Novel High Temperature Brazing Filler Metals Based on High Entropy Alloys

The CDT in Advanced Metallics is a partnership between the Universities of Sheffield and Manchester and the I-Form Advanced Manufacturing Centre, Dublin. CDT students undertake the CDT training programme at all three locations throughout the 4-year programme.

Brazing is a method of joining materials with many unique and useful features. In the process, an additional alloy, called a filler metal, is melted between the two parts to be joined. The liquid wets the joint and on solidification forms a relatively strong, conductive joint. Uniquely this method can join dissimilar metals and ceramics, and parts of thin cross section with no line of sight to the joint. Brazed joints feature in many applications, including in advanced systems such as aerospace jet engines.

This project builds on recent developments in a CDT project between both the Universities of Sheffield and Manchester, and the company VBC group. In this work, several novel brazing alloy filler metals were developed for the brazing of nickel, and we intend to build on this work, potentially developing these alloys further or designing new ones, looking at such developments as active metal brazing for the bonding of metals to ceramics, or very high temperature brazing for use at temperatures in excess of 1200°C.

The project will proceed from knowledge gained in an earlier PhD project. Objectives will include:
1) Validation at a larger scale of a new brazing alloy and brazing process;
2) Exploration of the behaviour of the alloy when processed by melt spinning to the form of an amorphous foil.
3) Development of the composition of the alloy and potentially trials of other new systems, including those adapted to active brazing (metal-ceramic joining) or brazing at high temperatures (>1250°C)

This project is highly collaborative between the Universities of Sheffield and Manchester and will use facilities at both partners. There will be significant interaction with VBC and likely also with their suppliers and customers, producing trial samples and evaluating the materials produced for various applications.

This project provides the opportunity to innovate, potentially developing patentable new alloys, yet also undertake fundamental work on the nature of alloys and processes in brazing. It will develop new innovative materials with a wide range of applications, including energy generation and transportation, and may facilitate creation of hybrid structures through joining dissimilar materials.