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Vacuum Brazing of Waveguide Components

Waveguide components refer to components that use waveguides to control or process electromagnetic waves. Can be used for directional transmission, matching, attenuation or absorption, power distribution, mode (waveform) transformation, isolation, filtering, phase shifting and amplification, frequency mixing, detection, frequency multiplication, oscillation, switching, etc. Such devices are widely used in communication transmission and various electronic devices.

The special-shaped waveguide device has a complex structure and needs to be fabricated by machining and vacuum brazing. The following is a related example process.

The special-shaped waveguide parts are manufactured as a whole into 2 pieces and vacuum brazed at one time. It includes two parts, an upper cavity and a lower cavity, the upper cavity has a debugging port, and the connection between the waveguide cavity and the main waveguide cavity is an arc connection. The thickness of the waveguide is 2mm, and the machining accuracy of the parts is required to be high. It is necessary to control the deformation and ensure the production efficiency at the same time.

Process flow:

Surface preparation

The brazing part has a clean oxide-free surface is an important prerequisite to ensure its welding quality. Because no flux is used, it is extremely important to remove oil and oxides on the surface of the weldment before welding. Degreasing aluminum and aluminum alloys in a detergent aqueous solution at a temperature of 60-70°C, cleaning for 5-10 minutes, and then rinsing with clean water. The following method was used to etch and remove the film: in 100g/L NaOH aqueous solution, the solution temperature was 20~40℃, the etching time was 2~4min, then washed in hot water, and placed in HNO3 aqueous solution for gloss treatment for 2~5min, Then wash in running cold water, and dry at a temperature not lower than 60 ℃ until there is no water stain at all. The cleaned parts should not be touched by hand or contaminated with other dirt, and should be brazed within 6 to 8 hours.

Solder placement and positioning

The solder grade is AlSiMg11.5-1.5 and the thickness is 0.1mm. Before soldering, the solder is cut into strips with a width of 2mm, wiped with acetone, and then placed and leveled in the upper cavity for spot welding. During spot welding, the workpiece and the electrode are required to be clamped and contacted reliably to avoid sparks during spot welding and damage to the surface of the parts. The fewer solder joints the better.

Determination of Welding Temperature Curve

Due to the great difference in thickness between the upper cavity and the lower cavity of the difference device, the heating is extremely uneven, and the welding fixture also needs to absorb heat, so the process parameters need to be carefully determined, the vacuum degree is 1*10-2Pa, and the heating and heating parameters are as follows :

Position the upper cavity and the lower cavity with pins and place them in the middle of the shielding box in the furnace. Use a spacer to flatten the differential, and use an adjusting spacer to support the flanges at both ends to prevent deformation due to heat; place the shielding box in the furnace. The center of the constant temperature zone in the furnace is pressed with a pressure block to ensure a suitable welding gap of 0.03~0.08mm. Use tweezers to place activated magnesium in the shielding box, a total of 40~50mg, divided into 3~4 pieces, and magnesium shall not be placed directly on the parts. After welding with the welding process parameters determined by the test, the welding quality and size, shape and position tolerances all meet the design requirements.

Vacuum brazing equipment selection: The RHVB series vacuum brazing furnace produced by SIMUWU is a high-quality product for the vacuum brazing process of tools and molds. The good temperature control accuracy and temperature control uniformity ensure the effective progress of the vacuum brazing process. SIMUWU specializes in the manufacture of vacuum furnaces, has more than ten years of relevant experience, and has a good reputation in the field of vacuum furnace manufacturing. The product line includes vacuum air quenching furnace, vacuum oil quenching furnace, vacuum brazing furnace, etc., which are widely sold in developed and developing countries.