Ilia Bobrov
Research Fellow, Guenter-Koehler-Institut für Fuegetechnik und Werkstoffpruefung GmbH (ifw Jena)
Mr. Bobrov studied materials science at the National Research Nuclear University MEPhI and received his degree in 2016. He began his career as a research fellow at the Leibniz Institute for Materials Engineering – IWT Bremen in the Physical Analytics Department. In 2022, he joined the ifw Jena as a group member in the Furnace-Based Processes Department. His current research focuses on several fields of conventional and hybrid joining technologies, including adhesive bonding, brazing, soldering, and diffusion bonding.
High-Temperature Adhesive–Metal Composites for Fixture-Free Brazing Applications
In modern manufacturing, brazing is widely used to join metallic components due to its ability to produce high-strength, leak-tight joints with minimal distortion. However, conventional brazing processes often require mechanical fixtures to maintain joint alignment while the filler metal is molten. These fixtures increase thermal inertia, energy consumption, cycle time, and production costs, while restricting joint geometry. High-temperature adhesives may provide stability during the brazing cycle, but they cannot replace the filler since they do not provide the required mechanical joint properties. Combining both joining technologies is therefore considered a promising hybrid approach.
In the present work, hybrid brazing systems were systematically investigated in which a metallic filler is embedded in high-temperature resistant inorganic adhesive matrices, forming self-supporting composite joints. The systems provide temporary fixation prior to heating, enabling handling, transport, and stacking of pre-assembled components and eliminating the need for conventional fixtures. Liquid glass–based adhesives were identified as suitable binders for such hybrid systems. Unlike organic binders used in conventional brazing pastes, these adhesives do not decompose; however, remaining phases appear to integrate into the joint microstructure without detrimental effects. The seam microstructure is regarded as a result of the interaction between filler metal and adhesive matrix. The resulting joints show homogeneous microstructures and favourable shear strength depending on filler-to-binder ratio, surface preparation, and process parameters. This hybrid approach enables fixture-free and wide-gap brazing, simplifies pre-brazing logistics, and may reduce energy consumption, cycle time, and production costs.
Co-author:
Dr D. Jakobi
Breakout III – Precision Application & Process Control – 16 September 2026 – 15:30 – 16:00 – Room Churchill – Ground Floor