Special fluxes for nitinol and nickel in high-performance military applications

Our flux EO-M-026 enables reliable soldering of nitinol and nickel alloys, making it ideal for military applications, UAVs and aerospace technologies.

April 16, 2026

Miniaturization, robustness, adaptive functions and maximum reliability are decisive factors for the performance of defence and aerospace technologies today. In this environment, nitinol, a nickel-titanium alloy with shape memory effect and superelasticity, is becoming increasingly important as a key material for innovative systems. With EO-M-026, Emil Otto offers a specially developed high-performance flux that is precisely tailored to the processing of nitinol and nickel alloys.

The challenge of soldering nitinol oxide layer as a critical factor

Soldering nitinol is one of the greatest challenges in assembly and connection technology. This is due to the extremely stable titanium oxide layer that forms immediately after contact with air and virtually prevents reliable wetting. Conventional fluxes reach their limits here, as they do not sufficiently remove the oxide layer or leave behind critical residues.

The flux EO-M-026 addresses precisely this problem:

High-performance flux EO-M-026 for safe processes

EO-M-026 has been specially developed to meet these requirements. The combination of highly active inorganic activators and complex organic additives enables:

The flux is zinc and halide-free, non-flammable and VOC-free, making it suitable for modern, safety-critical production environments.

By supporting common application methods, from manual processes to selective or laser-based soldering, EO-M-026 can be flexibly integrated into existing production lines.

EO-M-026

Cat. no. 6528

Recommended method of application
Soldering and tinning processes for nickel alloys as well as 'nitinol'

Ready-to-use, highly concentrated flux
Type: ISO-9454: 3311 (WEEE/RoHS compliant)

Enabler for military technologies and aerospace applications

EO-M-026 is a specialized flux that makes the processing of Nitinol process-safe and industrially scalable for the first time. This makes it a key enabler for modern military technologies, from UAV systems and adaptive structures to highly sensitive electronic assemblies.

This makes the flux a decisive process component, not only supporting but functionally indispensable for the production of resilient soldered joints. In the defense industry in particular, the quality of the joining technology determines the operational capability of complete systems.

Typical military applications of nitinol

Adaptive structures and morphing systems

Self-adjusting wings or air ducts in UAVs and missiles

Miniaturized microactuators

Applications in sensor technology, optics and portable equipment

Thermally controlled actuators and valves

Autonomous control mechanisms in fuel or hydraulic systems

Space and satellite technology

Reliable separation mechanisms without explosive components

Vibration and shock absorption

Protection of sensitive electronics in communication and target systems

These applications are based directly on the unique material properties of nitinol, in particular the shape memory effect and superelasticity, which enable mechanical functions without conventional drive systems.

Precision in processing as a success factor

As powerful as nitinol is, its processing is just as demanding. Even minor deviations in the soldering process can permanently impair the functional properties, such as the shape memory effect. Precisely controlled thermal processes, adapted solder alloys and precisely coordinated fluxes are therefore crucial. Only through this interaction can it be ensured that the mechanical and functional properties of the material are retained. This is a basic requirement for military systems with long operating times and extreme loads.

At a time when performance, reliability and miniaturization are decisive for technological superiority, connection technology therefore has a key role to play. EO-M-026 provides the necessary process basis for this.

Find out more about our fluxes for soft soldering a wide range of metals:

Emil replies

For which military and aerospace applications is Nitinol suitable when used in combination with specialized fluxes such as EO-M-026?

Nitinol is used in numerous military and aerospace applications, particularly where conventional materials reach their limits. These include adaptive structures in UAVs and missiles, thermally controlled actuators and valves, vibration and shock absorption systems, miniaturized microactuators, and reliable separation mechanisms in satellite technology. These applications benefit directly from unique properties such as shape memory and superelasticity.

How does the brazing process affect the shape memory effect and superelasticity of nitinol?

Even minor deviations in the brazing process can permanently impair the functional properties of nitinol. In particular, the shape memory effect and superelasticity are sensitive to thermal stresses. Therefore, precisely controlled temperature profiles, appropriately selected solder alloys, and suitable fluxes are necessary to preserve the material properties.

What properties must a flux have in order to reliably wet nitinol and nickel alloys?

A suitable flux must selectively remove the titanium oxide layer, activate surfaces that are difficult to wet, and at the same time minimize corrosive residues. In addition, high process stability, low-residue processing, and suitability for automated manufacturing processes are crucial. Ideally, it should be zinc- and halide-free, non-flammable, and VOC-free.

Why is soldering nitinol so technically challenging because of the titanium oxide layer?

Soldering nitinol is technically challenging because an extremely stable layer of titanium oxide forms immediately upon contact with air. This layer prevents the solder from reliably wetting the surface. Conventional fluxes are usually unable to effectively remove this oxide layer or leave behind critical residues, which significantly limits process reliability.