Powder brazing filler metals (PBFMs) feature a number of comparative advantages. Among others, these include a low energy consumption, an accurate dosage, a good brazeability, a short production time, and a high production efficiency. These filler metals have been used in the aerospace, automobile, and electric appliances industries. In this paper, the corrosion resistance of the Cu-Al joint brazed with flux-cored Zn-2Al filler metal

was investigated, comparing with that of the joint brazed with traditional Zn-2Al filler metal. Results showed that Zn-Al eutectic andα-Al were susceptible to the corrosion attack due to lower galvanic potential than other phases. The corrosion product of the Zn-Al eutectic was η-Zn and theα-Al dissolved after immersing for 48 h due to the galvanic corrosion. The corrosion resistance of the Cu-Al joint was improved by decreasing the area of phases, which was susceptible to the corrosion, whenreplacing traditional filler metal by flux-cored filler metal. The excessive Al dissolution resulted inlattice distortion and numerous microvoids, which in turn led to the formation and propagation of cracks. Residual oxides and flux in Cu-Al joints could also be the crack sources due to the generation of stress concentration in the process of corrosion. The shear strength of the joint brazed with flux-cored filler metal reached 34.5 MPa after immersing in 3.5 wt% NaCl solution for 18 days, which is higher than that of the joint brazed with traditional filler metal because of two aspects of decreasing brazing time and controlling brazing flux content.