Three dimensional (3D) printing technology has been widely used in metal manufacturing industry. This study focused on the vacuum brazing of 3D printed Inconel 718 superalloy with BNi-2 amorphous filler metal. Interfacial microstructure and element distribution revealed excellent wettability and spreadability of the filler metal as well as favorable brazability of the base material. Brazed joint could be divided into two distinct zones: isothermally solidified zone (ISZ) consisting of γ-Ni solid solution and diffusion-affected zone (DAZ) consisting of a large amount of precipitates besides γ-Ni solid solution. Microhardness reached peak values in DAZ. Although borides filled the gaps of base material’s grains to restrict grain boundary sliding and restrain the expansion of gaps, but its high hardness and brittleness would cause DAZ turn into weaker region when external loads were very large. The complete diffusion of B indicated the completion of isothermally solidified process. Precipitate CrB₂ with high hardness and brittleness was the key point of reducing the joint strength. Shear strength of the brazed joint was up to 802 MPa, and fracture morphology presented a mixed ductile-brittle fracture.

The changes that occur in the microstructure of crystalline and amorphous Cu-P-Sn-Ni filler metals during the heating process were studied by high-temperature microscopy, and the composition of solders at certain temperatures were analyzed by scanning electron microscopy and X-ray diffraction. The amorphous solder was observed to transform from amorphic to crystalline during the process of heating and distinct surface morphology changes were apparent, while the internal structure of the crystalline brazing filler metal was found to be relatively stable. During the heating process, the amorphous brazing filler metal formed a ϒ -Cu solid solution with a small amount of Cu ₃ P compounds, Cu ₈₈ Sn ₂₂ and (Cu, Ni) ₃ P phase compounds, ultimately forming the Cu ₈₈ Sn ₂₂ + Ni ₁₂ P ₅ + (Cu, Ni) ₃ P ₃ three-element eutectic structure.

Si₃N₄ ceramics and 304 stainless steel were brazed by Ti40Zr25B0.2Cu amorphous solder, and the interfacial microstructure of brazed joint Si₃N₄ ceramics/Ti40Zr25B0.2Cu/Cu/Ti40Zr25B0.2Cu/304 stainless steel was analyzed. The mechanical properties of the brazed joint were overtly affected by the brazing temperature and Cu foil thickness. The results revealed that the interface structure of the brazed joint might be 304 stainless steel/FeTi/Cu-Zr+Cu-Ti+Fe-Ti/Cu(s,s)/Cu-Zr+Cu-Ti+Fe-Ti/Ti-Si+Zr-Si/TiN/Si₃N₄ ceramics. The four-point bending strength of the brazed joint decreased sharply as the brazing temperature increased and reached a maximum of 76 MPa at 1223 K. Furthermore, as the Cu foil thickness was increased from 500 μm to 1000 μm, the joint strength rose to 90 MPa at 1223 K.

Si ₃ N ₄ ceramics and 304 stainless steel were joined by the Cu/Ag-Cu/Ti laminated filler metal. Interfacial microstructure of brazed joint and effect of brazing temperature and thickness of Cu foil on mechanical properties were studied in this paper. Research results showed that the interfacial microstructure of the brazed joint might be 304 stainless steel/TiFe ₂ /Ag-Cu eutectic+Cu(s,s)/Cu(s,s)/Cu(s,s)+Ag-Cu eutectic/Cu ₃ Ti+TiN/Si ₃ N ₄ ceramics. With the increasing of the brazing temperature, four-point bending strength of the brazed joint initially increased, then decreased. The bending strength reached the maximum value of 53 MPa at 1153 K when the thickness of Cu foil was 500 μm. The bending strength reached the maximum value of 57 MPa with 1 mm thickness Cu interlayer under the brazing temperature of 1153 K.

WC flexible cloth was fabricated by rolling WC powder that was pre-mixed with a nano-scale binder. BNi-2 braze alloy was used to braze the WC flexible cloth to a workpiece surface in a vacuum to form a compact composite coating. The composite coatings with different percentages of WC (wt.%, 30 %, 50 % and 80 %) have been successfully brazed onto Q345 steel substrate. Microscopic morphology and interfacial structure were characterized in terms of porosity, segregation and the distribution of WC particles. The bonding strength between the coating and the substrate was evaluated by shear test. The results showed that the segregation of WC particles appeared in all three coatings. With the increase of WC content in the coating, the segregation phenomenon was gradually reduced, and the WC particles were more closed. Furthermore, the thickness of the coating and matrix reaction layer was narrower, and more holes were found in the coating. Fracture of the 30 % and 50 % WC coatings was mainly plastic fracture, and the fracture of the 80 % WC coating was mainly brittle fracture accompanied by local plastic fracture. The maximum bonding strength of the coating to the substrate was determined to be 302 MPa.