Effect of Sn/Ni Addition on the Microstructure and Properties of Flux-Cored Brass Filler Metal and Its Brazed Joints

In this study, Sn and Ni powders were incorporated into the flux core of brass brazing filler metals, with alloying achieved via in situ synthesis during brazing. The effects of Sn/Ni single and composite additions on the microstructure, melting characteristics, wettability on Q235 steel, and tensile strength of corresponding brazed joints were systematically investigated. Sn addition increased the β-phase fraction, reduced the solidus temperature, and significantly improved wettability—with a maximum unit spreading area of 4.22 mm2/mg at 20 wt.% Sn (2.85 times that of the Sn/Ni-free baseline). However, coarse β-phase grains and their transformation to brittle β′-phase at room temperature resulted in no enhancement of joint tensile strength. Ni addition expanded the α-phase region, refined grains, and induced solid solution strengthening of the α-phase matrix; joint tensile strength peaked at 501 MPa at 20 wt.% Ni (65% higher than the baseline). Excessive Ni (≥40 wt.%) deteriorated wettability due to reduced molten superheat, and 50 wt.% Ni caused α-phase over-strengthening and embrittlement, leading to a sharp strength drop to 214 MPa. The composite addition of 3 wt.% Sn + 10 wt.% Ni reconstructed the filler metal into a refined, uniform grid-like (α + β) dual-phase structure without new phase formation, realizing synergistic optimization of wettability and mechanical properties. The co-added sample exhibited optimal performance, with a unit spreading area of 4.51 mm2/mg and joint tensile strength of 584 MPa (206% and 93% higher than the baseline, respectively). This improvement was attributed to the coupling of uniform stress dispersion by the grid-like microstructure and dual-element functional complementation (Sn for wettability and β-phase strengthening; Ni for grain refinement and α-phase strengthening). This work provides a feasible alloying modification strategy for brass flux-cored brazing filler metals, and the revealed microstructure-performance regulation mechanism offers a valuable reference for developing high-performance brass brazing filler metals.