How to Use Fusible Alloys

Fusible alloys are materials that melt at less then 149°C Electroforming Mandrels:
(300°F), well below the melting point of tin-lead eutectic The low melting point of fusible alloys makes them
solders and SAC alloys. Bismuth is the major component useful as mandrels for electroformed copper or nickel
of many of these alloys and influences the melting point, parts. A fusible alloy core is made by casting into a mold
as well as gives these materials the unique characteristic producing an electrically conductive pattern. Copper

APPLICATION NOTE
of expansion upon solidification. This expansion, which or nickel is then deposited on conductive surfaces to
can continue for hours or even days after solidification, the required thickness. The core is melted out, leaving
has proven to be a useful property in many processes. a dimensionally precise part with a smooth surface
finish. Fusible alloy mandrels can also be used when
Fusible alloys are classified as either eutectic or non-
the internal part configuration will not allow the removal
eutectic. In eutectic alloys, the melting point coincides
of a hard metal core.
with the freezing point. Non-eutectic alloys exhibit a
range between the melting and freezing points in which Bending:
the materials are “mushy” or “pasty.” Bending thin-walled tubing and channels without
adequate support can wrinkle, flatten, or rupture the
The composition and physical properties of common
part wall. Indalloy® 158 and Indalloy® 255 have long
fusible alloys are listed in the the tables that follow.
been used to support work pieces during bending or
Although most of the alloys do not have high strength
formatting to prevent damage.
or hardness, they have many industrial uses.
Normally, the part should be lubricated before filling
Anchoring:
to prevent galling and to allow for clean alloy removal.
This application takes advantage of alloy growth after
The growth property of the alloys ensures complete
freezing. In a typical installation, a part is mounted in
part filling, and flaws in a tube wall can often be
an oversized hole and the alloy is cast around the part.
detected by bulges or leaks of molten alloy through
Usually, about 24 hours is required for the alloy to grow
microscopic cracks.
sufficiently to hold the part securely. Indalloy® 217-440
has been used in such applications to hold punch Indalloy® 158 is the most widely used for this
heads for sheet metal piercing, vertical columns for application, and it can be melted out with hot water.
drop hammers, and permanent magnets in work Indalloy® 255 is used for tubes with diameters larger
holding fixtures. than 1.5 inches. However, a hot oil bath or oven heating
is required to reach the 124°C (255°F) melting
Chucks, Jigs, and Fixtures:
temperature.
Fusible alloys are used to hold delicate and irregular
shaped work pieces in polishing and machining With Indalloy® 255, the tube or channel can be bent
operations. For example, the extremely low melting point as soon as the alloy solidifies. Indalloy® 158 must be
of Indalloy® 117, Indalloy® 136, and Indalloy® 158 allows forced-chilled by immersion in cold, circulating water
them to be cast against eyeglass lenses to hold them immediately after filling. This results in a fine grain
through the grinding and polishing operations. Afterward, crystalline structure that adequately supports the
the alloy is melted off in warm water and re-circulated for work piece during formation.
reuse.
Encapsulation Molds:
Similarly, Indalloy® 158 and Indalloy® 281 are used to Molds for potting transformers and other electronic
secure thin foil sections on jet-engine turbine blades, components are often machined from aluminum or
allowing the critical “fir tree” pattern at the blade root to steel. These molds are permanent and can be used
be machined more accurately. In a typical fixture, the foil an almost unlimited number of times. They also are
section is positioned within a hollow hard steel matrix expensive, time-consuming to make, and difficult to
box. A fusible alloy is then cast around the foil and it modify.
grows to secure the blade for machining of the protruding
root section. After machining, the alloy is melted off for OVER →
reuse.
Form No. 97577 R3

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©2012 Indium Corporation
 How to Use Fusible Alloys
An alternative to these expensive molds is to utilize solder wave with flux operates with the solder bath at
the fusible alloy for molding. Preformed plastic cups only 149°C (300°F) to 166°C (330°F). Joint properties
are used for this application and are available in a are comparable to those of tin-lead solders, with
wide variety of shapes and sizes. After the component superior fatigue and copper dissolution characteristics.

APPLICATION NOTE
has been potted and the resin cured, this plastic mold Other alloys being considered include Indalloy® 38 and
becomes an integral part of the unit. Indalloy® 255.
The process of dip molding (slush casting) has been The increased use of fusible alloys in electronic
widely accepted by the electronics industry, where the applications has prompted ASTM to issue specification
configuration of the potted part permits easy withdrawal B-774-00, Standard Specification for Low Melting Point
of an alloy shell from the dip mandrel. Indalloy® 281 is Alloys, which describes alloy composition and use.
best suited to this application. After the unit is positioned
Conclusion:
in the tin-shell alloy cavity, encased in resin, and the
Fusible alloys are versatile industrial materials that can
resin cured, the alloy mold is cracked off and returned
be utilized in particular applications and processes to
to the melt pot for reuse.
reduce time and money. With the characteristics of low
Dies: melting point, expansion upon solidification and the
Drop hammer dies for short run sheet metal forming ease of reuse, fusible alloys are able to be utilized in
are made by casting fusible alloys against wood or applications that would prove difficult using a standard
plaster patterns. Dies made of these comparatively soft solder or alloy.
soft alloys will survive a quick blow but will deform in
a squeeze operation. Cross Reference: Indalloy®
Number to Alloy Composition
Fire Protection:
Indalloy ® Number Alloy Composition
One of the earliest uses of fusible alloys was as the melt-
out element in sprinkler heads. Several compositions Indalloy 19 51.0In/32.5Bi/16.5Sn
are used, depending on the location of the sprinkler Indalloy 38 52.5Bi/32.0Pb/15.5Sn
head in the building. Indalloy® 158 is the most commonly Indalloy 41 50.0Bi/28.0Pb/22.0Sn
used, but alloys covering the temperature range of 47°C Indalloy 42 46.0Bi/34.0Sn/20.0Pb
(117°F) to 100°C (212°F) are also used. Other fire Indalloy 53 67.0Bi/33.0In
protection applications include fusible links on fire doors Indalloy 102 47.5Pb/39.9Sn/12.6Bi
and safety plugs in pressure and process tanks.
Indalloy 117 44.7Bi/22.6Pb/19.1In/8.3Sn/5.3Cd
Electronic joining: Indalloy 136 49.0Bi/21.0In/18.0Pb/12.0Sn
In the last few years, considerable interest has Indalloy 147 48.0Bi/25.6Pb/12.8Sn/9.6Cd/4.0In
developed in the use of fusible alloys in electronic
Indalloy 158 50.0Bi/26.7Pb/13.3Sn/10.0Cd
assembly. This is due to the need for low-temperature
Indalloy 160-190 42.5Bi/37.7Pb/11.3Sn/8.5Cd
solders to assemble complex integrated circuits onto
printed circuit boards, and in surface mount assemblies. Indalloy 162 66.3In/33.7Bi
The objective is to permit wave soldering at Indalloy 174 57.0Bi/26.0In/17.0Sn
temperatures well below the 249°C (480°F) – 260°C Indalloy 217-440 48.0Bi/28.5Pb/14.5Sn/9.0Sb
(500°F) required with eutectic tin lead and SAC solders, Indalloy 255 55.5Bi/44.5Pb
thus preventing damage to sensitive electronic devices. Indalloy 281-338 60.0Sn/40.0Bi
Indalloy 281 and Indalloy 282 has shown great
® ® Indalloy 281 58.0Bi/42.0Sn
potential here with a melting point of 138°C (281°F) Indalloy 282 57.0Bi/42.0Sn/1.0Ag
and 139°C (282°F) to 140°C (284°F). A modified
wave soldering system that continuously floods the
OVER →

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©2012 Indium Corporation
 How to Use Fusible Alloys

Properties of Commonly Requested Fusible Alloys

Indalloy® Number 117 136 147 158 160-190 217-440 255 281 281-338
Alloy Composition 44.7Bi 49.0Bi 48.0Bi 50.0Bi 42.5Bi 48.0Bi 55.5Bi 58.0Bi 60.0Sn
22.6Pb 21.0In 25.6Pb 26.7Pb 37.7 Pb 28.5Pb 44.5Pb 42.0Sn 40.0Bi

APPLICATION NOTE
19.1In 18.0Pb 12.8Sn 13.3Sn 11.3Sn 14.5Sn
8.3Sn 12.0Sn 9.6Cd 10.0Cd 8.5Cd 9.0Sb
5.3Cd 4.0In
Liquidus °C (°F) 47 (117) 58 (136) 65 (149) 70 (158) 88 (190) 227 (441) 124 (255) 138 (281) 170 (338)
Temp °C (°F) E E E E E
Solidus °C (°F) 47 (117) 58 (136) 61 (142) 70 (158) 71 (160) 103 (217) 124 (255) 138 (281) 138 (280)
Density lbs/in3 0.3310 0.3255 0.3432 0.3461 0.3544 0.3360 0.3772 0.3093 0.2934
Tensile Strength lbs/in2 5,400 6,300 _ 5,990 5,400 13,000 6,400 8,000 7,500
Brinell Hardness No. 16.5 16.5 _ 14.5 15 19 15 23 23.5
Maximum Load 30 sec lbs/in2 _ _ _ 10,000 9,000 16,000 8,000 15,000 15,000
Safe Load Sustained _ _ _ 300 300 300 300 500 500
Electrical Conductivity
Compared with Pure Copper 4.5 2.4 _ 4 4.3 3 4 4.5 5
(% IACS)

Cumulative Growth and Shrinkage Time after Casting

2 min +0.0005 +0.0003 +0.0020 +0.0025 -0.0004 +0.0008 -0.0008 +0.0007 -0.0001
6 min +0.0002 +0.0002 +0.0022 +0.0027 -0.0007 +0.0014 -0.0011 +0.0007 -0.0001
30 min 0.0000 +0.0001 +0.0040 +0.0045 -0.0009 +0.0047 -0.0010 +0.0006 -0.0001
1 hour -0.0001 0.0000 +0.0046 +0.0051 0.0000 +0.0048 -0.0008 +0.0006 -0.0001
2 hour -0.0002 -0.0001 +0.0046 +0.0051 +0.0016 +0.0048 -0.0004 +0.0006 -0.0001
5 hour -0.0002 -0.0002 +0.0046 +0.0051 +0.0018 +0.0049 0.0000 +0.0005 -0.0001
500 hour -0.0002 -0.0002 +0.0052 +0.0057 +0.0025 +0.0061 +0.0022 +0.0005 -0.0001

Measurements are in inches per inch compared to cold mold dimensions. Test bar ½" x ½" x 10". Weight approximately one pound.
All data represent predictable characteristics and can be relied on only as a guide.
All information is for reference only. Not to be used as incoming product specifications.

This application note is provided for general information only. It is not of the products described which are sold subject exclusively to written warranties
intended, and shall not be construed, to warrant or guarantee the performance and limitations thereon included in product packaging and invoices.

[Link] askus@[Link]

ASIA: Singapore, Cheongju: +65 6268 8678

CHINA: Suzhou, Shenzhen, Liuzhou: +86 (0)512 628 34900
EUROPE: Milton Keynes, Torino: +44 (0) 1908 580400
USA: Utica, Clinton, Chicago: +1 315 853 4900
©2012 Indium Corporation