AEROSPACE MAM 4778D

MATERIAL Issued JUL 1989

SPECIFICATION Revised
Reaffirmed
FEB 1995
SEP 2000
Cancelled MAR 2003
Superseding MAM 4778C

Nickel Alloy, Brazing Filler Metal

92Ni - 4.5Si - 3.1B
980 to 1040 °C Solidus-Liquidus Range
UNS N99630

CANCELLATION NOTICE

This specification has been declared “CANCELLED” by the Aerospace Materials Division, SAE, as of
March, 2003. By this action, this document will remain listed in the Numerical Section of the Index
of Aerospace Material Specifications.

AMS 4778 covers the same material.

“CANCELLED” specifications are available from SAE.

SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely
voluntary, and its applicability and suitability for any particular use, including any patent infringement arising therefrom, is the sole responsibility of the user.”
SAE reviews each technical report at least every five years at which time it may be reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions.
Copyright 2003 Society of Automotive Engineers, Inc.
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying,
recording, or otherwise, without the prior written permission of SAE.

TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada)

Tel: 724-776-4970 (outside USA)
Fax: 724-776-0790
Email: custsvc@sae.org
SAE WEB ADDRESS: http://www.sae.org
 MAM 4778D SAE MAM 4778D

1. SCOPE:

1.1 Form:

This specification covers a nickel alloy in the form of wire, rod, strip, foil, and powder and a viscous
mixture (paste) of the powder in a suitable binder and procured in metric units.

1.1.1 AMS 4778 is the inch/pound version of this MAM.

1.2 Application:

This filter metal has been used typically for joining corrosion and heat resistant steels and alloys
requiring corrosion and oxidation resistant joints with good strength at elevated temperatures, but
usage is not limited to such applications. Also may be used as a corrosion and oxidation resistant
hard coating.

1.3 Safety - Hazardous Materials:

While the materials, methods, applications, and processes described or referenced in this
specification may involve the use of hazardous materials, this specification does not address the
hazards which may be involved in such use. It is the sole responsibility of the user to ensure
familiarity with the safe and proper use of any hazardous materials and to take necessary
precautionary measures to ensure the health and safety of all personnel involved.

2. APPLICABLE DOCUMENTS:

The following publications form a part of this specification to the extent specified herein. The applicable
issue of referenced publications shall be the issue in effect on the date of the purchase order.

2.1 ASTM Publications:

Available from ASTM, 1916 Race Street, Philadelphia, PA 19103-1187.

ASTM B 214 Sieve Analysis of Granular Metal Powders

ASTM D 638M Tensile Properties of Plastics (Metric)
ASTM E 18 Rockwell Hardness and Rockwell Superficial Hardness of Metallic Materials
ASTM E 354 Chemical Analysis of High-Temperature, Electrical, Magnetic, and Other Similar
Iron, Nickel, and Cobalt Alloys

2.2 U.S. Government Publications:

Available from DODSSP, Subscription Services Desk, Building 4D, 700 Robbins Avenue,
Philadelphia, PA 19111-5094.

MIL-STD-2073-1 DOD Material, Procedures for Development and Application of Packaging

Requirements

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3. TECHNICAL REQUIREMENTS:

3.1 Composition:

Shall conform to the percentages by weight shown in Table 1, determined by wet chemical methods
in accordance with ASTM E 354, by spectrochemical methods, or by other analytical methods
acceptable to purchaser.

TABLE 1 - Composition
Element min max
Carbon -- 0.06
Silicon 4.00 5.00
Phosphorus -- 0.02
Sulfur -- 0.02
Boron 2.75 3.50
Cobalt (3.1.1) -- 0.10
Titanium -- 0.05
Aluminum -- 0.05
Iron (3.1.2) -- 0.50
Zirconium -- 0.05
Selenium (3.1.1) -- 0.005 (50 ppm)
Nickel remainder

3.1.1 Determination not required for routine acceptance.

3.1.2 Iron to 1.50% by weight maximum is permissible in strip and foil products (tape form).

3.2 Condition:

The product shall be supplied in the following condition:

3.2.1 Wire and Strip: Powder bonded in a suitable plastic.

3.2.2 Rod: As cast, with fins and projections removed.

3.2.3 Foil and Powder: As fabricated.

3.2.4 Paste: Shall consist of 84 to 90% by weight powder in a suitable binder and, unless otherwise
ordered, shall not contain flux.

3.3 Properties:

Filler metal shall conform to the following requirements:

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3.3.1 Wire and Strip:

3.3.1.1 Burn-Off of Plastic: The plastic used for bonding powder to form wire and strip shall burn off,
leaving no adherent residue, when the product is heated to a temperature not higher than 980 °C.

3.3.1.2 Tensile Strength: Shall be not lower than 2.5 MPa, determined in accordance with ASTM D 638M,
Speed B.

3.3.1.3 Metallic Content: The ratio of volume of powder to volume of plastic binder shall be the largest
possible consistent with the requirements of 3.3.1.1 and 3.3.1.2.

3.3.2 Rod, Foil, and Powder: When specified, properties shall be as agreed upon by purchaser and
vendor.

3.3.3 Paste:

3.3.3.1 Paste shall have a shelf life of not less than six months; not more than thorough mixing shall be
required to restore paste for use during that time.

3.3.3.2 Paste, without flux, shall leave no adherent residue when heated in a protective atmosphere to a
temperature higher than 540 °C.

3.3.4 When used as a hard coating, alloy shall melt quickly and shall flow freely under neutral oxy-
acetylene flame, without bubbling or boiling, to produce an adherent deposit free from porosity due
to blow-holes, gas cavities, or slag inclusions.

3.3.4.1 Alloy, deposited as in 3.3.4, shall have hardness not lower than 25 HRC, or equivalent (See 8.3),
determined in accordance with ASTM E 18.

3.4 Quality:

The product, as received by purchaser, shall be uniform in color, quality, and condition and free from
foreign materials and from imperfections detrimental to its working qualities. Rod and powder shall
have a metallic luster. Wire, strip, and foil shall be clean, sound, smooth, and free from ragged
edges, splitting, damaged ends, and other imperfections detrimental to usage of the product.

3.5 Sizes and Tolerances:

The product shall be supplied in the following standard sizes and to the tolerances shown:

3.5.1 Wire:

3.5.1.1 Diameter Standard Sizes: Shall be 0.8, 1.6, 3.2, and 4.8 millimeters.

3.5.1.2 Diameter Tolerances: Shall be ±0.10 millimeter.

3.5.2 Rod:

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3.5.2.1 Nominal Dimensions: Shall be as ordered.

3.5.2.2 Diameter Tolerances: Shall be as shown in Table 2.

TABLE 2 - Diameter Tolerances

Diameter Tolerance, %
Millimeters of Diameter
0.8 ±20
1.6 ±15
3.2 ±10
4.8 ±10

3.5.2.3 Concentricity: When long lengths are supplied as welded composites of cast lengths, diameters
of the adjacent sections shall be concentric within ±0.8 millimeter.

3.5.3 Strip and Foil: When specified, properties shall be as agreed upon by purchaser and vendor.

3.5.4 Powder:

3.5.4.1 Mesh Designations: Shall be 60, 100, 140, 200, and 325.

3.5.4.2 Powder shall be supplied in accordance with the limits on particle size distribution shown in Table
3, unless another distribution is specified. Tests shall be in accordance with ASTM B 214.

TABLE 3 - Particle Size Distribution

Mesh Designation U.S. Standard Sieve
60 Through a No. 40 sieve - 100%
Through a No. 60 sieve - 95% min
Through a No. 325 sieve - 10% max

100 Through a No. 60 sieve - 100%

Through a No. 100 sieve - 95% min
Through a No. 325 sieve - 15% max

140C On a No. 100 sieve - 0.5% max

On a No. 140 sieve - 10% max
Through a No. 325 sieve - 20% max

140F On a No. 100 sieve - 0.5% max

On a No. 140 sieve - 10% max
Through a No. 325 sieve - 55% max

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TABLE 3 - Particle Size Distribution (Continued)

Mesh Designation U.S. Standard Sieve
200 On a No. 140 sieve - 0.5% max
On a No. 200 sieve - 10% max
Through a No. 325 sieve - 65% max

325 On a No. 200 sieve - 0.5% max

On a No. 325 sieve - 10% max
Through a No. 325 sieve - 90% min

3.5.4.2.1 When a mesh designation is not specified, 140F mesh shall be supplied.

4. QUALITY ASSURANCE PROVISIONS:

4.1 Responsibility for Inspection:

The vendor of the product shall supply all samples for vendor’s tests and shall be responsible for
performing all required tests. Purchaser reserves the right to sample and to perform any confirmatory
testing deemed necessary to ensure that the product conforms to the requirements of this
specification.

4.2 Classification of Tests:

4.2.1 Acceptance Tests: All technical requirements, other than shelf life of paste (3.3.3.1), are
acceptance tests and shall be performed on each lot.

4.2.2 Periodic Tests: Tests for shelf life of paste (3.3.3.1) are periodic tests and shall be performed at a
frequency selected by the vendor unless frequency is specified by purchaser.

4.3 Sampling and Testing:

Shall be in accordance with the following:

4.3.1 Composition: One sample shall be taken from each furnace charge except that powder produced
from consecutive furnace charges and collected together, without teardown of the atomizing
equipment, shall constitute a batch, from which one sample shall be taken.

4.3.2 Properties Except Shelf Life of Paste: One sample from each lot.

4.3.2.1 A lot shall be all product, other than powder or paste, which has been tested and found to
conform to Table 1, in the same temper and size, and presented for vendor’s inspection at one
time.

4.3.2.2 A lot of powder shall be a uniform blend of powder produced from one or more furnace charges,
each meeting the requirements of Table 1, as modified by 4.3.1, and presented for vendor’s
inspection at one time.

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4.3.2.3 A lot of paste shall be that paste produced from a single lot of powder, combined with binder from
the same manufacturing batch, and presented for vendor’s inspection at one time.

4.4 Reports:

The vendor of the product shall furnish with each shipment a report showing the results of tests on
each lot or batch to determine conformance to the composition requirements and stating that the
product conforms to the other technical requirements. This report shall include the purchase order
number, lot number or numbers, MAM 4778C, form, size, and quantity.

4.5 Resampling and Retesting:

Not applicable.

5. PREPARATION FOR DELIVERY:

5.1 Identification:

5.1.1 Shall be as agreed upon by purchaser and vendor.

5.1.2 Each exterior container or package shall be permanently and legibly marked with not less than the
following information:

NICKEL ALLOY, BRAZING FILLER METAL

MAM 4778C
LOT NUMBER ________________________________________________________
MANUFACTURER’S IDENTIFICATION _____________________________________
NOMINAL DIMENSIONS ________________________________________________
WEIGHT _____________________________________________________________

5.1.2.1 Each container and package of paste shall also be marked with the date of manufacture.

5.2 Packaging:

5.2.1 The product shall be suitably wrapped, sealed, and boxed or otherwise packaged for protection
against injury and contamination during shipment and under normal dry storage conditions.

5.2.2 Packages of filter metal shall be prepared for shipment in accordance with commercial practice
and in compliance with applicable rules and regulations pertaining to the handling, packaging, and
transportation of the filler metal to ensure carrier acceptance and safe delivery.

5.2.3 For direct U.S. Military procurement, packaging shall be in accordance with MIL-STD-2073-1,
Level C, unless Level A is specified in the request for procurement.

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6. ACKNOWLEDGMENT:

A vendor shall mention this specification number and its revision letter in all quotations and when
acknowledging purchase orders.

7. REJECTIONS:

Filler metal not conforming to this specification, or to modifications authorized by purchaser, will be
subject to rejection.

8. NOTES:

8.1 A change bar ( l ) located in the left margin is for the convenience of the user in locating areas where
technical revisions, not editorial changes, have been made to the previous issue of this specification.
An (R) symbol to the left of the document title indicates a complete revision of the specification,
including technical revisions. Change bars and (R) are not used in original publications, nor in
specifications that contain editorial changes only.

8.2 This filler metal has an approximate solidus temperature of 980 °C and an approximate liquidus
temperature of 1040 °C.

8.3 Hardness conversion tables for metals are presented in ASTM E 140.

8.4 Definitions of terms used in AMS are presented in ARP1917.

8.5 For direct U.S. Military procurement, purchase documents should specify not less than the following:

Title, number, and date of this specification

Form and size of filler metal desired
Quantity of filler metal desired
Level A packaging, if required (See 5.2.3).

8.6 Similar Specifications:

AWS A5.8, Class BNi-3, is listed for information only and shall not be construed as an acceptable
alternate unless all requirements of this MAM are met.

8.7 Filler metal meeting the requirements of this specification has been classified under Federal Supply
Classification (FSC) 3439.

8.8 Key Words:

Wire, rod, strip, foil, powder, paste, hard coating

PREPARED UNDER THE JURISDICTION OF AMS COMMITTEE “F”

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