Vacuum Brazing Technology

What is vaccum brazing?

Vacuum brazing is a manufacturing process used to join components to achieve higher thermal performance and lighter solutions. A vacuum brazed cold plate is a water-cooled plate that is made by machining two metal plates with internal channels and fin structures (usually folded or skived fins), which are then carefully sealed in a vacuum chamber for heating. The filler metal with a lower melting point is melted by capillary action under the appropriate process conditions into the joints of the cold plate and joins the two plates with internal channels and fin structures to form an internal flow channel.

Vacuum Brazed Liquid Cold Plate Structure

Type of Brazed Liquid Cold Plate	Copper Cold Plate, Aluminum Cold Plate	Material Option	AL6061、AL6063、C101、C102、C110、C145
Liquid Cold Plate Coolant	Water, Glycol solutions, Dielectrics, Oils and Synthetic hydrocarbons (PAO)	Processing Technology	CNC Turning, Milling, Vacuum Brazing
Surface Treatment	Anodizing, Painting, etc	Internal Fin Structure	Machined fins, folded fins, stamped fins, extruded fins，skived fin, etc.

Advantages of Vacuum Brazing

Excellent Jointing

Vacuum brazing is carried out in a controlled environment with low or no oxygen, producing clean, oxide-free joints. Moreover, the melting point of the metals used in vacuum brazing is usually lower than that of the base metal, resulting in joints with high mechanical strength and a strong bond between components.

Sealing without Leakage

Vacuum brazing produces joints that are highly resistant to leakage, making it suitable for applications that require a high degree of gas or liquid tightness. This makes vacuum brazing ideal for the manufacture of components used in vacuum systems, heat exchangers, medical equipment and other critical applications.

Wide Range of Compatible Materials

Vacuum brazing is compatible with a wide range of materials, including stainless steel, aluminum, copper and various alloys. This versatility can be used to join dissimilar metals to create complex and efficient components.

Reduced Distortion and Stress

Vacuum welding is performed in the absence of air. Uniform heating and cooling reduces component distortion and residual stress, prevents warping, ensures dimensional stability and maintains component integrity.

Precise Connection

Vacuum brazing can precise control of process parameters such as brazing temperature and heating rate, resulting in consistent and repeatable joints. This high level of control can be the production of high quality parts with tight tolerances.

Enhanced Thermal Properties

Vacuum welding can use brazing alloys with excellent thermal conductivity and joints can efficient heat transfer, making it ideal for applications that require excellent heat dissipation.

Make Complex Wate Cold Plate

The fluidity and wettability of vacuum brazing material is very good, which can weld more complex water-cooled plate structures and narrow passages, especially for thin-walled and micro-channel liquid-cooled plates. Vacuum brazing improves the yield of water-cooled plates, and obtains a solid and clean working surface.

Vacuum Brazing Quality Control Process

Quality control is an important part of the vacuum brazing process to ensure that the brazed joints meet the necessary standards and requirements.

Scanning Acoustic Microscope

Material Inspection

Raw materials such as filler metals, fluxes and base metals are inspected in detail to verify their quality, characteristics and compatibility with the vacuum brazing process.

Joint Preparation

Verify and ensure that the joint preparation process meets the necessary standards. Joint preparation, joint selection, joint cleaning, surface polishing, etc., is critical, as it affects the quality and performance of brazed joints.

Brazing Process Control

The brazing process should be carried out in a controlled atmosphere (i.e. vacuum conditions) to prevent material contamination and oxidation. Quality control at this stage includes temperature controlled brazing time, vacuum monitoring and quenching to ensure that the brazing process meets the necessary parameters and produces the desired results.

Visual Inspection

After vacuum brazing, brazed joints are inspected using visual inspection techniques to verify joint integrity and durability. Quality control at this stage includes the use of non-destructive /destructive inspection techniques, such as X-rays and microstructural analysis, to check the quality of the joints.

Final Inspection

Final inspection is the last step in the vacuum brazing process and involves a thorough check of the finished product using a variety of quality control test methods. The inspection includes the overall quality of the product, its performance, compliance with specifications, and conformance to the standards necessary for the vacuum brazing process.

Vacuum Brazing Applications

Vacuum brazed cold plates offer unparalleled flexibility in design as they are not limited by the pressure tube cold plate bending radius restrictions. Heat pipes can also be embedded in the plate to improve heat dissipation. Machined fins, folded fins, stamped fins, extruded fins, and other internal fin structures can be inserted inside the vacuum brazed cold plate to increase the surface area in contact with the working fluid and provide greater and better heat transfer. As a result, vacuum brazed cold plates are the liquid-cooled thermal modules of choice for power generation, electric vehicle batteries, fuel cell assemblies, and a variety of military, medical and avionics applications.

Power Electronics

Vacuum brazed water cooling panels are used for power electronic components such as Sic.GBTs and thyristors. These power electronic components require reliable and efficient cooling when installed in compact spaces.

Medical and Aerospace

Vacuum brazing is used to produce heating and cooling components, microchannel heat exchangers, aircraft components and sensors. Aluminum's ability to flow heat and the deoxidizing properties of the vacuum bell brazing process make it suitable for joining components in these industries.

New Energy Batteries

Vacuum brazed water cooling plates are used to manufacture water cooling plates for new energy batteries. These cooling plates help dissipate the heat generated by the battery during operation.

Cryogenic Applications

Vacuum brazing is also used in cryogenic systems, such as cryostats, where components need to be connected precisely to ensure an ammonia-tight chamber.

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