Filling a hole by capillary flow of liquid metal-equilibria and instabilities

The importance of the problem of hole-filling by a molten metal lies in the application of brazing for repairs in space, under microgravity conditions. The negligible effects of gravity and dominance of capillary forces can be approximated under terrestrial conditions, provided that the holeand the quantity of liquid are small, as quantified by the Bond number. In this paper, we report experimental results, modeling, and analysis of the hole-filling problem using the liquid aluminum brazing alloy on aluminum substrate. Depending on the hole size, the capillary driven flow may resultin the hole being either filled or not filled. The equilibrium problem (energy minimization) has multiple solutions in some regions of the parameter space. Therefore, the experimental outcomes may depend on the availability of sufficiently strong perturbation, required to dislodge the system froma metastable equilibrium. We report good agreement between experimental results and theoretical/computational predictions. In general, a deeper and narrower hole favors the filled outcome.