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<p>Critical aerospace components such as hot-section structures of turbine engines, thrust chambers of rocket motors, and lightweight heat exchangers must operate reliably under extreme service conditions.&#xa0;The demand has driven the widespread use of high-temperature materials, including nickel-based superalloys, titanium alloys, TiAl-based intermetallic compounds, and ceramics and their composite materials. However, the increasing complexity of structural configurations and the growing need for multi-material integration have promoted high-temperature brazing as a preferred joining technique due to its exceptional adaptability to complex geometries and dissimilar material systems. Nevertheless, such brazed joints commonly suffer from intense interfacial reactions, brittle intermetallic formation, and limited long-term mechanical stability under service conditions.&#xa0;This paper systematically reviews the research progress on high-temperature brazing using different filler metal systems in aerospace applications, including Ni-based, Ti-based, precious metal-based, and high-entropy filler metals. The compositional characteristics, application scope, and current research status of each filler metal system are comprehensively summarized. The main research directions and technological developments in filler metal systems are delineated by comparing joining behaviors and optimization strategies across different joining systems. Furthermore, in light of engineering application requirements, future perspectives are discussed regarding filler metal design, process optimization, and service reliability evaluation.</p>

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Review: high-temperature brazing in aerospace—challenges and filler metal optimization strategies for different joining systems

  • 期刊论文

  • 发表日期：

    2026年7月31日

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  • Yunpeng Li,
  • Jian Qin,
  • Weimin Long,
  • Sujuan Zhong,
  • Guanxing Zhang,
  • Peng Guo,
  • Zongye Ding,
  • Xuyang Chen,
  • Shiyang Wang

摘要

Critical aerospace components such as hot-section structures of turbine engines, thrust chambers of rocket motors, and lightweight heat exchangers must operate reliably under extreme service conditions. The demand has driven the widespread use of high-temperature materials, including nickel-based superalloys, titanium alloys, TiAl-based intermetallic compounds, and ceramics and their composite materials. However, the increasing complexity of structural configurations and the growing need for multi-material integration have promoted high-temperature brazing as a preferred joining technique due to its exceptional adaptability to complex geometries and dissimilar material systems. Nevertheless, such brazed joints commonly suffer from intense interfacial reactions, brittle intermetallic formation, and limited long-term mechanical stability under service conditions. This paper systematically reviews the research progress on high-temperature brazing using different filler metal systems in aerospace applications, including Ni-based, Ti-based, precious metal-based, and high-entropy filler metals. The compositional characteristics, application scope, and current research status of each filler metal system are comprehensively summarized. The main research directions and technological developments in filler metal systems are delineated by comparing joining behaviors and optimization strategies across different joining systems. Furthermore, in light of engineering application requirements, future perspectives are discussed regarding filler metal design, process optimization, and service reliability evaluation.