A hollow aluminum structure that will be brazed includes at least one brazing sheet having a filler metal layer clad onto a core layer. The core layer is composed of aluminum or an aluminum alloy containing less than 0.2 mass % Mg. The filler metal layer is composed of an aluminum alloy that contains Si: 4.0-13.0 mass % and Bi: 0.01-0.3 mass %, and further contains Li: 0.004-0.08 mass % and/or Be: 0.006-0.12 mass %, the filler metal layer containing less than 0.1 mass % Mg. The hollow aluminum structure is assembled such that the filler metal layer is present at locations that will form both an interior-facing brazed joint and an exterior-facing brazed joint. Then, flux is applied onto the filler metal layer at the location that will form the exterior brazed joint, and the hollow aluminum structure heated in an inert gas atmosphere to form the interior brazed joint and the exterior brazed joint.

A secondary cell manufacturing method includes placing a current collector terminal on a plurality of laminated current collector foils from a lamination direction of the current collector foils. The current collector terminal has a first end portion, and a second end portion forming a cutout with the first end portion. The second end portion includes a base part, and a thin-walled part having a smaller thickness than the base part. The secondary cell manufacturing method includes welding the plurality of current collector foils to the current collector terminal by scanning the plurality of current collector foils disposed in the cutout with a laser beam along the first extension direction toward the second end portion while irradiating the plurality of current collector foils with the laser beam.

A substrate support and method of forming a substrate support are described herein. In one example, a substrate support includes an aluminum body having an upper surface configured to support a large area substrate, a heater element, and a filler material. The aluminum body has a groove formed therein. The heater element is disposed in the groove. The filler material is in contact with the heater element and fills the groove. The contact between the filler material and the perimeter of the heater element is the only material interface within the groove, and the filler material has a larger grain size than a grain size of the aluminum body.

An apparatus, material and method for forming a brazing sheet has a composite braze liner layer of low melting point aluminum alloy and 4000 series braze liner. The low melting point layer of the composite braze liner facilitates low temperature brazing and decrease of the diffusion of magnesium from the core into the composite braze liner. The reduction of magnesium diffusion also lowers the formation of associated magnesium oxides at the braze joint interface that are resistant to removal by Nocolok flux, thereby facilitating the formation of good brazing joints through the use of low temperature controlled atmosphere brazing (CAB) and Nocolok flux. The apparatus also enables the production of brazing sheet materials with high strength and good corrosion property.

A brazing sheet (1) includes a core material (11) composed of an Al alloy that contains 0.20-3.0 mass % of Mg; and a filler material (12) layered on the core material and composed of an Al alloy that contains Mg, 6.0-13.0 mass % of Si, and more than 0.050 mass % and 1.0 mass % or less of Bi. The Mg concentration of the filler material becomes continuously lower in a direction from a boundary (122) with the core material to an outermost surface (121). The Mg concentration of the filler material is 0.150 mass % or less at a first depth from the outermost surface that is ⅛ of a thickness (t.sub.f) of the filler material and is 5-90% of the amount of Mg in the core material at a second depth from the outermost surface that is ⅞ of the thickness of the filler material.

An aluminum alloy brazing sheet used for brazing of an aluminum material in an inert gas atmosphere or in vacuum is formed of a two-layer material in which a brazing material and a core material are stacked. The core material is formed of an aluminum alloy and has a grain size of 20 to 300 μm, and the aluminum alloy contains Mn of 0.50 to 2.00 mass %, Mg of 0.40 to 2.00 mass %. Si of 1.50 mass % or less, Fe of 1.00 mass % or less, and Ti of 0.10 to 0.30 mass %, with the balance being aluminum and inevitable impurities. The brazing material is formed of an aluminum alloy containing Si of 4.00 to 13.00 mass % with the balance being aluminum and inevitable impurities. In a drop-type fluidity test, a ratio α (α=K.sub.a/K.sub.b) of a fluid coefficient K.sub.a is 0.50 or more.

An aluminum alloy brazing sheet formed of a brazing material, an intermediate material, a core material, and a brazing material. The intermediate material contains Mg of 0.40 to 6.00 mass % and Zn exceeding 2.00 mass % and equal to or less than 8.00 mass %. The core material contains Mg of 0.40 to 2.00 mass % and one or two or more of Mn of 1.80 mass % or less, Si of 1.50 mass % or less, Fe of 1.00 mass % or less, Cu of 1.20 mass % or less, Ti of 0.30 mass % or less, Zr of 0.30 mass % or less, and Cr of 0.30 mass % or less. Each of the core material and the intermediate material has a grain size of 20 to 300 μm, and each of the brazing materials comprises Si of 4.00 to 13.00 mass %.

A conductor for a power transmission cable has a first conductor element and a second conductor element connected by a welding joint. The welding joint has a welding material alloy where the welding material alloy has an Al content of from 90% to 98% by weight, a Ni content of from 2% to 8% by weight, and a content of other metals and/or substances from 0% to 2% by weight, based on the total weight of the welding material alloy, wherein the Al content, Ni content and content of other metals and/or substances sum up to 100% by weight.

A composition for welding or brazing aluminum comprises silicon (Si) and magnesium (Mg) along with aluminum in an alloy suitable for use in welding and brazing. The Si content may vary between approximately 5.0 and 6.0 wt %, and the Mg content may vary between approximately 0.15 wt % and 0.50 wt %. The alloy is well suited for operations in which little or no dilution from the base metal affects the Si and/or Mg content of the filler metal. The Si content promotes fluidity and avoids stress concentrations and cracking. The Mg content provides enhanced strength. Resulting joints may have a strength at least equal to that of the base metal with little or no dilution (e.g., draw of Mg). The joints may be both heat treated and artificially aged or naturally aged.

An aluminum alloy brazing sheet is formed of a brazing material, an intermediate material, a core material, and a brazing material. The intermediate material contains Mg of 0.40 to 6.00 mass %, and has total of contents of Mn, Cr, and Zr being 0.10 mass % or more. The core material contains Mg of 0.20 to 2.00 mass % and one or two or more of Mn of 1.80 mass % or less, Si of 1.50 mass % or less, Fe of 1.00 mass % or less, Cu of 1.20 mass % or less, Ti of 0.30 mass % or less, Zr of 0.30 mass % or less, and Cr of 0.30 mass % or less. Each of the core material and the intermediate material has a grain size of 20 to 300 μm, and each of the brazing materials contain Si of 4.00 to 13.00 mass %.