Research on Ultrasonic Soldering Process of Sn/Cu/Sn Clad Filler Metal for 6061Al and Corrosion Resistance of Joints

WANG Shuo; JIANG Xiaohan; Chen Wei; BI Zhenglong; LI You; JIAN Xiaojun; LIU Runxuan; YAN Jiuchun

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Research on Ultrasonic Soldering Process of Sn/Cu/Sn Clad Filler Metal for 6061Al and Corrosion Resistance of Joints

更新时间：2026-09-22

- Research on Ultrasonic Soldering Process of Sn/Cu/Sn Clad Filler Metal for 6061Al and Corrosion Resistance of Joints
- Electronic Product Reliability and Environmental Testing Pages: 1-11(2026)
- 作者机构：
  
  1.首都航天机械有限公司，北京 100076
  2.哈尔滨工业大学材料结构精密焊接与连接全国重点实验室，黑龙江哈尔滨 150006
- 作者简介：
- 基金信息：
- DOI：
  CLC：
- Received：19 May 2026，
  
  Revised：2026-08-22，
  
  Accepted：24 August 2026，
  
  Online First：21 September 2026，
- 稿件说明：
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王硕,姜小涵,陈伟等.Sn/Cu/Sn夹层钎料超声钎焊6061Al工艺及接头耐蚀性研究^★[J].电子产品可靠性与环境试验,DOI:10.3969/j.issn.1672-5468...001.

WANG Shuo,JIANG Xiaohan,Chen Wei,et al.Research on Ultrasonic Soldering Process of Sn/Cu/Sn Clad Filler Metal for 6061Al and Corrosion Resistance of Joints[J].Electronic Product Reliability and Environmental Testing,
王硕,姜小涵,陈伟等.Sn/Cu/Sn夹层钎料超声钎焊6061Al工艺及接头耐蚀性研究^★[J].电子产品可靠性与环境试验,DOI:10.3969/j.issn.1672-5468...001. DOI：

WANG Shuo,JIANG Xiaohan,Chen Wei,et al.Research on Ultrasonic Soldering Process of Sn/Cu/Sn Clad Filler Metal for 6061Al and Corrosion Resistance of Joints[J].Electronic Product Reliability and Environmental Testing, DOI：10.3969/j.issn.1672-5468...001.

摘要

6061Al兼具优异的塑韧性与导热性能，广泛应用于电子散热构件，超声钎焊能够在低温条件下实现6061Al钎焊，但钎焊接头耐腐蚀性能较差。为改善6061Al超声钎焊接头的耐腐蚀性能，本文制备Sn/Cu/Sn夹层钎料，重点探究超声钎焊时间对钎料内Al-Cu金属间化合物物相种类及弥散分布特性的影响规律，并通过盐雾试验与力学测试表征接头性能，分析其耐蚀机理。试验结果表明，较短超声作用时间下，Al-Cu化合物弥散均匀性差，接头耐蚀性能薄弱，盐雾试验3天后发生失效；延长超声时间可优化化合物分布，显著提升接头耐蚀性，盐雾试验4天后接头剪切强度仍维持在50 MPa以上。机理分析表明，弥散分布的Al-Cu化合物可通过Al的选择性腐蚀弱化界面宏观腐蚀，同时促进钎料表面生成致密腐蚀产物膜，阻隔离子传输、减慢阴阳极反应，有效降低接头腐蚀速率。

Abstract

6061Al possesses excellent ductility and thermal conductivity，making it widely used in electronic heat dissipation components. Ultrasonic soldering enables joining of 6061Al at low temperatures；however，the corrosion resistance of the resulting joints remains poor. To improve the corrosion resistance of ultrasonically brazed 6061Al joints，a Sn/Cu/Sn layered filler metal was developed in this study. The focus was on investigating how ultrasonic soldering time affects the types and dispersed distribution characteristics of Al-Cu intermetallic compounds within the filler metal. Joint performance was evaluated through salt spray tests and mechanical testing， and the corrosion resistance mechanism was analyzed. Results show that with shorter ultrasonic exposure times， the dispersion uniformity of Al-Cu compounds is poor，leading to weak corrosion resistance-joints failed after just three days in the salt spray test. Extending the ultrasonic duration optimizes compound distribution and significantly enhances joint corrosion resistance， maintaining shear strength above 50 MPa even after four days in the salt spray test. Mechanistic analysis reveals that the dispersed Al-Cu compounds can weaken macroscopic interface corrosion through selective dissolution of Al， while simultaneously promoting the formation of a dense corrosion product film on the filler surface. This film effectively blocks ion transport and slows down anodic and cathodic reactions，thereby substantially reducing the corrosion rate of the joint.

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references

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