Arc spraying Ag-based coating on aluminum alloy surface and its low-temperature soldering behavior
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摘要: 在波导器件中，铝合金壳体较差的润湿性制约了其与微带电路板之间大面积、可靠低温钎焊连接. 通过电弧喷涂技术在5A06铝合金表面制备了厚度约为80 μm的Ag-15%Ni(质量分数)单一涂层和Ni-5%Al/Ag-15%Ni(质量分数)复合涂层，以提升Sn-Pb钎料在其表面的润湿性. 对比研究了两种涂层的显微结构、涂层界面结合性能、低温钎焊行为及钎焊接头剪切失效机制. 结果表明，涂层与铝合金基板间形成了良好的界面结合，并且两种涂层均具有较好的低温焊接性. 其中，Ag-15%Ni单一涂层与铝合金基板的结合强度为40 MPa，喷涂后铝合金基板与T2紫铜形成的钎焊接头抗剪强度为26 MPa. 相较而言，Ni-5%Al /Ag-15%Ni复合涂层展现出更佳的涂层结合强度(42 MPa)和钎焊接头抗剪强度(31 MPa).Abstract: In waveguide devices, large-area and reliable low-temperature soldering bonding between the aluminum alloy shell and the microstrip circuit board were difficult because of the poor wettability of the Al alloy. In this study, Ag-15%Ni coating layer and Ni-5%Al/Ag-15%Ni composite coating layers with a thickness approximately of 80 μm were prepared on the surface of 5A06 Al alloy by arc spraying technology to improve the wettability of Sn-Pb alloy solder on the Al alloy surface. Comparable studies were performed on the microstructure, interfacial bonding behavior, low-temperature soldering behavior of the two kinds of coating layers, and the shearing failure mechanism of joints were investigated. Results showed that sound interfacial bonding was realized between the coating layer and the Al alloy substrate. Moreover, the two kinds of coating layers both exhibited good solderability at low-temperature. The bonding strength between the Ag-15%Ni coating layer and the Al alloy substrate was 40 MPa, and the shear strength of the soldering joint formed by the sprayed aluminum alloy substrate and T2 copper was 26 MPa. While, the Ni-5%Al/Ag-15%Ni composite coatings exhibited better bonding strength with the Al alloy substrate (42 MPa) and higher shear strength of the soldering joint (31 MPa) than the Ag-15%Ni single coating layer.
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图 1 Ag-15Ni涂层形貌
Figure 1. Morphology of the Ag-15Ni coating. (a) macroscopic morphology; (b) micromorphology
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图 2 Ag-15Ni涂层表面XRD衍射图谱
Figure 2. XRD diffraction pattern of the Ag-15Ni coating layer surface
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图 3 Ag-15Ni涂层与铝基板界面处的元素线分布
Figure 3. Elemental line distribution image at the interface between Ag-15Ni coating layer and Al substrate
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图 4 Ni-5Al涂层形貌
Figure 4. Morphology of the Ni-5Al coating layer. (a) macroscopic morphology; (b) micromorphology
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图 5 Ni-5Al涂层表面XRD衍射图谱
Figure 5. XRD diffraction pattern of the Ni-5Al coating layer surface
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图 6 Ni-5Al涂层与铝基板界面处的元素线扫描结果
Figure 6. Element line scanning results at the interface between Ni-5Al coating layer and Al substrate
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图 7 Ni-5Al/Ag-15Ni复合涂层形貌
Figure 7. Micromorphology of Ni-5Al/Ag-15Ni composite coating layer
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图 8 Ni-5Al/Ag-15Ni复合涂层与铝基板界面处元素线扫描结果
Figure 8. Element line scanning results at the interface between Ni-5Al/Ag-15Ni composite coating layer and Al substrate
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图 10 不同涂层界面处SEM图
Figure 10. SEM images of the coating layer interfaces. (a) Ag-15Ni/Al substrate; (b) Ni-5Al/Al substrate; (c) Ni-5Al/Ag-15Ni
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图 11 涂层的断口形貌
Figure 11. Fracture morphology of the coating layers. (a) Ag-15Ni single coating layer; (b) Ni-5Al/Ag-15Ni composite coating layer
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图 12 不同涂层钎焊接头的截面显微图
Figure 12. Cross-section micrographs of the soldered joints with different coating layers. (a) Ag-15Ni single coating layer; (b) Ni-5Al/Ag-15Ni composite coating layer
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图 13 不同涂层钎焊接头的抗剪强度
Figure 13. Shear strength of soldered joints with different coating layers
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图 14 不同涂层钎焊接头剪切断口截面形貌
Figure 14. Cross-section images of shearing failed joints with different coating layers. (a) Ag-15Ni single coating layer; (b) Ni-5Al/Ag-15Ni composite coating layers
表 1 涂层的制备参数
Table 1 Preparation parameters of the coatings
涂层类型 电弧喷涂
丝材喷涂电压
U/V喷涂电流
I/A喷枪移动速度
v/(m·min−1)喷枪口到工件
距离S/cm气体压力
P/MPa气源
类型Ag-15Ni单一涂层 Ag-15Ni 34 280 10 15 0.6 纯N2 Ni-5Al/Ag-15Ni
复合涂层Ni-5Al 34 150 10 18 0.6 纯N2 Ag-15Ni 34 280 12 15 0.6 纯N2 
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表 2 Ag-15Ni涂层内局部位置的元素含量(原子分数, %)
Table 2 Elemental compositions in local positions inside the Ag-15Ni coating layer
测试点 Ni Al Ag O 1 97.36 — 2.64 — 2 7.27 ― 92.73 ―
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表 3 Ni-5Al涂层内部局部位置的元素含量(原子分数, %)
Table 3 Elemental compositions in local positions inside the Ni-5Al coating layer
测试点 Ni Al Ag O 1 13.59 56.28 ― 30.13 2 88.31 11.69 ― ―
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表 4 Ni-5Al/Ag-15Ni复合涂层内部局部位置的元素含量 (原子分数, %)
Table 4 Elemental compositions in local positions inside the Ni-5Al/Ag-15Ni composite coating layer
测试点 Ni Al Ag O 1 21.85 ― 78.15 ― 2 8.80 ― 91.20 ―
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表 5 不同涂层钎焊接头中局部位置的元素含量(原子分数，%)
Table 5 Elemental compositions in local positions inside the soldered joints with different coating layer
测试点 Ni Cu Ag Sn Pb 主要物相 1 ― ― 66.02 31.57 2.41 Ag3Sn 2 6.99 41.66 ― 44.74 6.61 (Cu,Ni)6Sn5 3 ― ― 76.16 23.84 ― Ag3Sn 4 ― ― 73.55 26.45 ― Ag3Sn 5 ― ― ― 37.57 62.43 Sn-Pb过共晶
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