Abstract
A laboratory-scale characterization of the cast-on-strap joining process has been conducted using an existing leadantimony strap alloy and low-antimony lead and leadcalcium alloy lugs. Increasing mould temperature in the range from 150 to 250 °C only marginally decreases the initially rapid cooling rate of the strap melt, but considerably decreases the subsequent cooling rate when the strap melt starts to solidify. Increasing the melt pouring temperature from 500 to 550 °C has little influence on the overall cooling characteristics of the strap. Joining of the lug/strap couple can be characterized by lack of fusion, partial fusion and complete fusion from the strap surface to the lug tip. At a mould temperature of 150 °C, a significant lack of fusion and considerable porosity are observed. The degree of fusion increases significantly when the mould temperature is increased from 150 to 200 °C. Pretinning effectively eliminates lack of fusion and considerably reduces the level of porosity. This most likely results from the presence of lower melting point material between the lugs and strap. There is good fusion and low porosity for leadcalcium alloy joints for which a more aggressive acid-based flux is used.
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