High-frequency Induction Brazing Process and Performance Improvement of Copper/Aluminum Dissimilar Metal Pipe Joints

LUO Shougen; HUANG Weiqing; LIU Jinxiang; CHE Xingtao; HUANG Shisheng; YU Dingkun; QIAO Xue

doi:10.7512/j.issn.1001-2303.2025.04.13

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High-frequency Induction Brazing Process and Performance Improvement of Copper/Aluminum Dissimilar Metal Pipe Joints
Vol. 55, Issue 4, Pages: 100-106(2025)
Received：11 December 2024，

Published：20 April 2025
DOI： 10.7512/j.issn.1001-2303.2025.04.13
稿件说明：

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罗寿根，黄魏青，刘金湘，等.铜/铝异种金属管接头的高频感应钎焊工艺及性能提升［J］.电焊机，2025，55（4）：100-106. DOI： 10.7512/j.issn.1001-2303.2025.04.13.

LUO Shougen, HUANG Weiqing, LIU Jinxiang, et al.High-frequency Induction Brazing Process and Performance Improvement of Copper/Aluminum Dissimilar Metal Pipe Joints[J].Electric Welding Machine, 2025, 55(4): 100-106. DOI： 10.7512/j.issn.1001-2303.2025.04.13.

摘要

针对铜和铝异种金属管接头开发了高频感应钎焊工艺，重点关注不同加热位置及工艺参数对焊缝外观及熔深的影响。通过对比两种常用钎料（BAl67CuSi和BZn78Al22）的焊接效果，发现BZn78Al22钎料由于更低的熔点和更优的润湿性，更适合铜/铝异种金属的感应钎焊。分析了不同加热位置对钎料润湿性和焊缝成形的影响，确定了最佳加热位置：首段加热时，线圈底部与铝管顶部之间高度差为4~5 mm；二段加热时，线圈端面低于管座端面1 mm。此外，通过调整感应加热功率和时间，实现了分段加热控制，有效避免了母材熔蚀并提高了焊缝熔深。最终，采用优选的钎料和工艺参数获得的铜/铝异种金属感应钎焊接头，其焊缝熔深超过95%，致密性良好，且承压能力达到 13.81 MPa，满足设计要求。该研究为铜铝异种金属管接头的高质量连接提供了理论依据和技术支持。

Abstract

A high-frequency induction brazing process for copper and aluminum dissimilar metal pipe joints was developed

focusing on the effects of different heating positions and process parameters on the appearance and penetration depth of the weld seam. Firstly

by comparing the welding effects of two commonly used brazing alloys (BAl67CuSi and BZn78Al22)

it was found that the BZn78Al22 brazing alloy

due to its lower melting point and better wettability

is more suitable for induction brazing of copper/aluminum dissimilar metals. Secondly

the influence of different heating positions on the wettability of the brazing alloy and the formation of the weld seam was analyzed

and the optimal heating position was determined: during the first stage of heating

the height difference between the bottom of the coil and the top of the aluminum pipe is 4~5 mm; during the second stage of heating

the end face of the coil is 1 mm lower than the end face of the pipe seat. In addition

by adjusting the induction heating power and time

segmented heating control was achieved

effectively avoiding parent material melting and improving weld penetration depth. Finally

the copper/aluminum dissimilar metal induction brazed joint obtained using the selected brazing alloy and process parameters has a weld penetration depth exceeding 95%

good compactness

and a pressure-bearing capacity of 13.81 MPa

meeting the design requirements. This study provides a theoretical basis and technical support for high-quality connections of copper and aluminum dissimilar metal pipe joints.

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