Brazing Remedy for Solidification Cracking During Copper to Aluminum Welding

Fusion welding for dissimilar joints such as aluminum to copper is very difficult because of the crack initiation at the fusion line, then progress to joint failure. By this work, the brazing by filler metal ( Brass, 60% Cu and 40% Zn) which have a melting temperature more than aluminum melting temperature, so that brazing will contain some fusion at the aluminum side, this will help in the process of crack remedy. The bonding mechanism shows welded cracks by brazing capillary, and the structure near the brazing line is dendritic structure. While the cracking at the fusion process for the same bond shows cracks with casting structure.