The use of modern thermal spraying techniques for filler metal application may offer new solutions for brazing complex metal components without fluxing agents, when the spraying processes are fitted to the requirements of the following brazing process. The necessary coating parameters always depend on the kind of base material, the geometry of the joint, the used filler metal, and the chosen heating process for brazing (heating in vacuum or protective atmosphere furnaces, inductive or flame heating etc.). Copper and nickel based alloys are typical filler metals for brazing complex components made of stainless steel (heat exchanger, fuel pipe systems, exhaust systems, catalytic devices etc.). Using these examples, the results of brazing experiments and technical aspects of thermally sprayed braze coatings compared with conventional filler metal application techniques are discussed.

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