Brazing sheet, article formed from brazing sheet, and method of forming article

Abstract

A brazing sheet, an article formed from or including all or a portion of a brazing sheet, and a method of forming an article are provided. The brazing sheet includes a brazing layer and a core layer. The brazing layer includes a 4XXX series aluminum alloy. The core layer comprises a first aluminum alloy comprising, in weight percent based on the total weight of the first aluminum alloy: 0.2 to 0.6 silicon; 1.5 to 2 of manganese; 0.01 to 0.2 of titanium; 0.5 to 2.5% of copper; 0 to 0.5 of iron; 0 to 0.5 of magnesium; 0 to 0.5 of zinc; 0 to 0.3 of chromium; from 0 to 0.25 of zirconium; optionally, elements are pudiated; impurities; and aluminum. The first aluminum alloy satisfies the relational expression # imgabs 0 # # imgabs 1 #, and [Mg], [Fe], [Cr], and [Si] are weight percentage concentrations of manganese, iron, chromium, and silicon in the first aluminum alloy, respectively.

Description

[0001] Cross - Reference to Related Applications

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 480,625, filed on January 19, 2023, the content of which is incorporated herein by reference. Technical Field

[0003] The present disclosure relates to brazing sheets, articles formed from or including brazing sheets, and methods of forming the articles. Background Art

[0004] Various devices, such as, for example, heat exchangers, can be formed from stacked specially designed metal sheets, such as, for example, brazing sheets. The function of a plate heat exchanger is to circulate two fluids (e.g., liquids, refrigerants, or combinations thereof) on opposite sides of the plates, thereby effecting heat exchange between the fluids. There are many challenges in designing acceptable brazing sheets and sourcing raw materials for producing brazing sheets. Summary of the Invention

[0005] According to a non-limiting aspect of the present disclosure, a brazing sheet is provided, the brazing sheet including a brazing layer and a core layer. The brazing layer comprises a 4XXX series aluminum alloy. The core layer includes a first aluminum alloy, the first aluminum alloy comprising, based on the total weight of the first aluminum alloy in weight percent: 0.2 to 0.6 silicon; 1.5 to 2 manganese; 0.01 to 0.2 titanium; 0.5 to 2.5 copper; 0 to 0.5 iron; 0 to 0.5 magnesium; 0 to 0.5 zinc; 0 to 0.3 chromium; 0 to 0.25 zirconium; optionally incidental elements; impurities; and aluminum. The first aluminum alloy satisfies the relationship and [Mg], [Fe], [Cr], and [Si] are the weight percent concentrations of manganese, iron, chromium, and silicon, respectively, in the first aluminum alloy.

[0006] According to another non-limiting aspect of the present disclosure, an article is provided, the article including a component or being formed from a component, the component including a structural element that includes all or a portion of a brazing sheet. The brazing sheet includes a brazing layer and a core layer. The brazing layer comprises a 4XXX series aluminum alloy. The core layer includes a first aluminum alloy, the first aluminum alloy comprising, based on the total weight of the first aluminum alloy in weight percent: 0.2 to 0.6 silicon; 1.5 to 2 manganese; 0.01 to 0.2 titanium; 0.5 to 2.5 copper; 0 to 0.5 iron; 0 to 0.5 magnesium; 0 to 0.5 zinc; 0 to 0.3 chromium; 0 to 0.25 zirconium; optionally incidental elements; impurities; and aluminum. The first aluminum alloy satisfies the relationship And [Mg], [Fe], [Cr], and [Si] are the weight percentage concentrations of manganese, iron, chromium, and silicon in the first aluminum alloy, respectively.

[0007] According to yet another non - limiting aspect of the present disclosure, there is provided a method for forming an article. The method includes bringing a first component comprising a first material into contact with a second component comprising all or a portion of a brazing sheet, the brazing sheet including a brazing layer and a core layer. The brazing layer comprises a 4XXX series aluminum alloy. The core layer includes a first aluminum alloy that comprises, by weight percentage based on the total weight of the first aluminum alloy: 0.2 to 0.6 silicon; 1.5 to 2 manganese; 0.01 to 0.2 titanium; 0.5 to 2.5 copper; 0 to 0.5 iron; 0 to 0.5 magnesium; 0 to 0.5 zinc; 0 to 0.3 chromium; 0 to 0.25 zirconium; optionally incidental elements; impurities; and aluminum. The first aluminum alloy satisfies the relationship And [Mg], [Fe], [Cr], and [Si] are the weight percentage concentrations of manganese, iron, chromium, and silicon in the first aluminum alloy, respectively. The method includes brazing the first component to the second component by a process including at least one of controlled atmosphere brazing and vacuum brazing.

[0008] It should be understood that the inventions disclosed and described in this specification are not limited to the aspects outlined in this summary of the invention. After considering the following detailed description of various non - limiting and non - exhaustive aspects in accordance with this specification, the reader will understand the foregoing details as well as other details. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The features and advantages of the examples, and the manner of achieving them, will become more apparent and the examples will be better understood by reference to the following description taken in conjunction with the drawings, in which:

[0010] Figure 1 is a schematic side view of a first non - limiting embodiment of a brazing sheet according to the present disclosure;

[0011] Figure 2 is a schematic side view of a second non - limiting embodiment of a brazing sheet according to the present disclosure;

[0012] Figure 3 is a schematic side view of a third non - limiting embodiment of a brazing sheet according to the present disclosure;

[0013] Figure 4 is a schematic side view of a fourth non - limiting embodiment of a brazing sheet according to the present disclosure;

[0014] Figure 5 is a schematic side view of a fifth non - limiting embodiment of a brazing sheet according to the present disclosure; and

[0015] Figure 6 is a flowchart showing non - limiting embodiments of a method for forming an article in accordance with the present disclosure.

[0016] The illustrations set forth herein show certain embodiments in one form, and such illustrations should not be construed as limiting the scope of the appended claims in any way. Detailed Description

[0017] Various embodiments are described and illustrated herein to provide an overall understanding of the structure, function, and use of the disclosed articles and methods. The various embodiments described and illustrated herein are non - limiting and non - exhaustive. Thus, the present invention is not limited by the descriptions of the various non - limiting and non - exhaustive embodiments disclosed herein. Instead, the present invention is defined only by the claims. Features and characteristics described and / or illustrated in connection with various embodiments may be combined with the features and characteristics of other embodiments. Such modifications and variations are intended to be included within the scope of this specification. Thus, the claims may be modified to recite any feature or characteristic that is expressly or inherently described or otherwise expressly or inherently supported in this specification. Additionally, the applicant reserves the right to modify the claims to affirmatively disclaim a feature or characteristic that may exist in the prior art. The various embodiments disclosed and described in this specification may include, consist of, or consist essentially of the various features and characteristics described herein.

[0018] Any reference herein to "various embodiments", "some embodiments", "one embodiment", "an embodiment", "non - limiting embodiments", or similar phrases means that a particular feature, structure, step, or characteristic described in connection with the example is included in at least one embodiment. Thus, the phrases "various embodiments", "some embodiments", "one embodiment", "an embodiment", "non - limiting embodiments", or similar phrases that appear in the specification do not necessarily refer to the same embodiment. Moreover, in one or more embodiments, the particular features, structures, steps, or characteristics described may be combined in any suitable manner. Thus, a particular feature, structure, step, or characteristic illustrated or described in connection with one embodiment may be combined, in whole or in part, with the features, structures, steps, or characteristics of one or more other embodiments without limitation. Such modifications and variations are intended to be included within the scope of the embodiments of the present disclosure.

[0019] The various non-limiting embodiments of the alloys discussed in connection with the present disclosure optionally include intentionally added incidental elements that may, for example, assist in the production of the alloys and / or improve one or more properties or characteristics of the alloys. For example, certain non-limiting embodiments of the alloys according to the present disclosure may include one or more of the intentionally added incidental grain refining elements and / or one or more deoxidizing elements. In various non-limiting embodiments, based on the total weight of the alloy, the total concentration of the incidental elements in the alloys according to the present disclosure is preferably not more than 1 wt%, and based on the total weight of the alloy, the concentration of any single incidental element is preferably not more than 0.2 wt%.

[0020] The various non-limiting embodiments of the alloys discussed in connection with the present disclosure may include impurities. As used herein, "impurities" are elements or other materials that may be present in the alloys according to the present disclosure in relatively small concentrations but are not intentionally added to enhance production or affect the properties or characteristics of the alloys. For example, impurities in the alloys according to the present disclosure may be present in small concentrations due to, for example, the inevitable or unintentional presence of impurities in the feed materials, ingress from the local atmosphere during melting, refining, or other processing, or contamination due to contact with the processing equipment. In various non-limiting embodiments, based on the total weight of the alloy, the total concentration of the impurities in the alloys discussed in the present disclosure is preferably not more than 0.15 wt%, and based on the total weight of the alloy, the concentration of any single impurity is preferably not more than 0.05 wt%.

[0021] Brazing sheets typically contain alloying elements that would be valuable if they could be separated from the used or waste brazing sheets or from used or waste articles formed from or including the brazing sheets. Brazing sheets typically include multiple layers, each with its own compositional specification. Separating the layers of a brazing sheet, removing individual alloying elements from a brazing sheet, or separating a particular layer from an article that includes or is formed from a brazing sheet can be challenging. Thus, the brazing sheet or article must be recycled as a whole, without separating the layers or regions in which the desired elements are present. The concentrations at which certain alloying elements are present in used brazing sheets or used articles may not be suitable as recycled feed materials for the production of certain aluminum alloy sheets that will be incorporated into brazing sheets. For example, some alloying elements may be present in a brazing sheet or used article at a concentration that will have an adverse effect on the properties of the core layer of the brazing sheet (such as corrosion resistance, grain size, and / or other microstructural properties of the core layer).

[0022] The present inventors have determined that a balance between chemical modification of elements present in the scrap material and additional intentional element additions can provide desired properties for aluminum alloy sheets for brazing sheets. The brazing sheets provided by the present disclosure can exhibit good recyclability, as well as acceptable or excellent formability, corrosion resistance, brazability, strength, and resistance to diffusion. Embodiments of the brazing sheets according to the present disclosure can include a brazing layer and a core layer. The brazing layer comprises a 4XXX series aluminum alloy. The core layer includes a first aluminum alloy, the first aluminum alloy comprising, by weight percent based on the total weight of the first aluminum alloy: 0.2 to 0.6 silicon; 1.5 to 2 manganese; 0.01 to 0.2 titanium; 0.5 to 2.5 copper; 0 to 0.5 iron; 0 to 0.5 magnesium; 0 to 0.5 zinc; 0 to 0.3 chromium; 0 to 0.25 zirconium; optionally incidental elements; impurities; and aluminum. The first aluminum alloy satisfies the relationship and [Mg], [Fe], [Cr], and [Si] are the weight percent concentrations of manganese, iron, chromium, and silicon, respectively, in the first aluminum alloy.

[0023] As used herein, the term "core layer" refers to the backing layer of the brazing sheet. In various non-limiting embodiments, the "core layer" can be substantially disposed at the center of the brazing sheet. However, the position of the core layer in the brazing sheet according to the present disclosure is not limited to the center of the brazing sheet. The core layer may or may not be covered by another layer of the brazing sheet on its two faces, and for example, the core layer can be disposed and partially or completely exposed on one side of the brazing sheet. Thus, in various non-limiting embodiments, the core layer of the embodiments of the brazing sheet according to the present disclosure can be completely covered by other layers of the brazing sheet on both sides, at least one side is at least partially exposed, or at least one side is completely exposed.

[0024] Referring to Figure 1 , a brazing sheet 100 is provided. The brazing sheet 100 includes a core layer 102 and a brazing layer 104. In various non-limiting embodiments, the core layer 102 and the brazing layer 104 are joined (e.g., roll-bonded) together to form the brazing sheet 100. Figure 1 The brazing sheet 100 shown includes two layers. However, the brazing sheet 100 can include one or more additional layers, as described herein, for example, as Figure 2 and 5 shown three layers, as Figure 4 shown four layers, or as Figure 3 shown five layers.

[0025] Referring again to Figure 1, as a step in the production process, the brazing sheet 100 can be brazed to form a product. For example, in the brazing step, an assembly including a component and the brazing sheet 100 is heated to a temperature at least as high as the melting temperature of the brazing layer 104 so that the brazing layer 104 melts and flows to wet the surface of the component, and then solidifies to form a suitable brazed joint between the brazing sheet 100 and the component. In various embodiments, the temperature at which the assembly is heated in the brazing step can be high enough to dissolve the soluble phase in the brazing sheet 100. Generally, during brazing, the assembly is heated to a temperature in the range of 590 °C to 610 °C. In various embodiments, the heated assembly is rapidly cooled, which can minimize the precipitation of undesirable soluble phases.

[0026] During brazing, it is desirable that the core layer 102 does not melt so that the core layer 102 maintains the desired strength, structural integrity, and corrosion resistance. For example, in various embodiments, the core layer 102 can have a core solidus temperature higher than the brazing temperature to which the brazing sheet 100 is subjected. For example, the core layer 102 can include a core solidus temperature of at least 600 °C, such as at least 605 °C, at least 610 °C, or at least 615 °C.

[0027] In various embodiments, the core layer 102 can be non - homogeneous and H - tempered. As used herein, H - tempering has the meaning provided in ANSI H35.1 / H35.1(M) - 2017. The core layer 102 can form a brown band, thereby having corrosion resistance. The brown band can form in the core layer 102 when silicon diffuses from the brazing layer 104 to the core layer 102 during the brazing process and forms precipitates with manganese and iron in the solid solution. The brown band in the core layer 102 can contain small - scale Al x Mn y Si z or Al x (Mn,Fe,Cr) y Si z dispersion phases, which form a band near the interface between the brazing layer 104 and the core layer 102. The formation of the dispersion phases at this interface pulls manganese out of the solid solution and creates a region in the brazing sheet 100 that is more electrochemically negative, which is anodic relative to the center of the brazing sheet 100, thereby increasing the overall corrosion resistance of the core layer 102. Since the presence of silicon in the core layer 102 can affect the formation of the brown band and the core solidus temperature, highly corrosion - resistant core layers containing high levels of silicon generally do not rely on the formation of the brown band to achieve corrosion resistance. The inventors have determined that silicon and other alloying elements can be present in the core layer 102 while achieving the desired brown band formation by adjusting the chemistry of the core layer 102 to compensate for the high - silicon levels that may result from using scrap brazing sheets in the production of the brazing sheet 100, thereby improving corrosion resistance.

[0028] The core layer 102 of the brazing sheet 100 comprises a first aluminum alloy, such as an aluminum alloy of the 3XXX series. The first aluminum alloy may comprise, by weight percentage based on the total weight of the first aluminum alloy, 0.2 to 0.6 silicon, for example, 0.2 to 0.55 silicon, 0.25 to 0.55 silicon, 0.25 to 0.5 silicon, 0.3 to 0.55 silicon, 0.3 to 0.5 silicon, 0.3 to 0.45 silicon or 0.3 to 0.4 silicon. The silicon content may be derived from the scrap materials used in producing the core layer 102.

[0029] It has been found that maintaining an appropriate balance of certain elements in the core layer 102 can allow the core layer 102 to contain a large amount of scrap materials and still exhibit the desired properties. For example, the first aluminum alloy may satisfy the relationship and [Mg], [Fe], [Cr] and [Si] are the weight percentage concentrations of manganese, iron, chromium, and silicon in the first aluminum alloy, respectively. X may be at least 3.1, for example, at least 3.2, at least 3.3, at least 3.4, at least 3.5, at least 3.6, at least 3.7, at least 3.8, at least 3.9 or at least 4. X may not be greater than 10. For example, X may be in the range of 3.1 to 10.

[0030] In various non-limiting embodiments, maintaining an appropriately high weight ratio of manganese to silicon in the core layer 102 can allow the core layer 102 to contain a large amount of scrap materials and still exhibit the desired properties. For example, the weight ratio of manganese to silicon in the first aluminum alloy may be at least 3.1, for example, at least 3.2, at least 3.3, at least 3.4, at least 3.5, at least 3.6, at least 3.7, at least 3.8, at least 3.9 or at least 4. The weight ratio of manganese to silicon may not be greater than 10. For example, the weight ratio of manganese to silicon in the first aluminum alloy may be in the range of 3.1 to 10.

[0031] The first aluminum alloy may comprise, by weight percentage based on the total weight of the first aluminum alloy, 1.5 to 2 manganese, for example, 1.55 to 2 manganese, 1.6 to 2 manganese, 1.65 to 2 manganese, 1.7 to 2 manganese, 1.6 to 1.95 manganese, 1.6 to 1.9 manganese, 1.65 to 1.9 manganese or 1.65 to 1.85 manganese.

[0032] The first aluminum alloy may comprise, by weight percentage based on the total weight of the first aluminum alloy, 0.01 to 0.2 titanium, for example, 0.03 to 0.2 titanium, 0.05 to 0.2 titanium or 0.1 to 0.2 titanium.

[0033] The first aluminum alloy of the core layer 102 may comprise, by weight percent based on the total weight of the first aluminum alloy: 0.2 to 0.6 silicon; 1.5 to 2 manganese; 0.01 to 0.2 titanium; 0.5 to 2.5 copper; 0 to 0.5 iron; 0 to 0.5 magnesium; 0 to 0.5 zinc; 0 to 0.3 chromium; 0 to 0.25 zirconium; optionally incidental elements; impurities; and aluminum. In various non-limiting embodiments, the first aluminum alloy comprises, by weight percent based on the total weight of the first aluminum alloy: 0.2 to 0.5 silicon; 1.6 to 2 manganese; 0.01 to 0.2 titanium; 0.5 to 1 copper; 0.1 to 0.4 iron; 0 to 0.1 magnesium; 0 to 0.25 zinc; 0 to 0.3 chromium; 0 to 0.25 zirconium; optionally incidental elements; impurities; and aluminum. In certain non-limiting embodiments, the first aluminum alloy comprises, by weight percent based on the total weight of the first aluminum alloy: 0.3 to 0.4 silicon; 1.6 to 2 manganese; 0.01 to 0.2 titanium; 0.5 to 1 copper; 0.1 to 0.4 iron; 0 to 0.1 magnesium; 0 to 0.25 zinc; 0 to 0.3 chromium; 0 to 0.25 zirconium; optionally incidental elements; impurities; and aluminum.

[0034] The chemical properties of the core layer 102 can be modified to include another corrosion protection mechanism in addition to or as an alternative to the brown band. For example, the core layer 102 can be modified to include a certain concentration of copper to provide current protection for the core layer 102. An excessively high copper concentration may have an adverse effect on the properties of the core layer 102. In various examples, the core layer 102 can have a weight ratio of copper to manganese in the first aluminum alloy of no greater than 1, for example, no greater than 0.9 or no greater than 0.8.

[0035] The core layer 102 can be formed from an ingot comprising, for example, at least 10% scrap material, such as at least 20% scrap material, at least 30% scrap material, at least 40% scrap material, or at least 50% scrap material. The remaining material in the ingot can be feedstock material, such as primary aluminum (e.g., P1020 grade) and optionally a hardener. The amount of scrap material contained can be balanced based on the amount of silicon or other alloying elements contained in the scrap material. For example, the amount of scrap material and the amount of feedstock material in the melt of the ingot forming the core layer 102 can be selected such that the resulting core layer 102 comprises no greater than 0.6 wt% silicon by weight based on the total weight of the core layer 102. The scrap material can be, for example, pre-consumer waste (e.g., return stock) generated from the manufacture of brazing sheet or its components and / or post-consumer waste obtained from third-party sources. The scrap material can include, for example, scrap brazing sheet, used or scrap articles formed from or including brazing sheet, and / or scrap material from other sources.

[0036] The brazing layer 104 of the brazing sheet 100 comprises a second aluminum alloy, such as a 4XXX series aluminum alloy. In various non-limiting embodiments, the second aluminum alloy comprises, by weight percentage based on the total weight of the aluminum alloy: 5 to 15 silicon; 0 to 2 magnesium; 0 to 1 iron; 0 to 3 zinc; 0 to 2 copper; 0 to 1 manganese; 0 to 0.3 bismuth; optionally incidental elements; impurities; and aluminum. The brazing layer 104 exhibits a brazing layer solidus temperature that is lower than the core layer solidus temperature, e.g., at least 5 °C, at least 10 °C, at least 15 °C, at least 20 °C, at least 25 °C, or at least 30 °C lower than the core layer solidus temperature. Ensuring that the brazing layer solidus temperature is sufficiently lower than the core layer solidus temperature enables a brazing process in which the brazing sheet 100 is heated to a suitable temperature to melt the brazing layer 104 while the core layer 102 remains substantially solid.

[0037] The thickness of each layer in the brazing sheet 100 can be configured based on the desired structural properties of an article (e.g., a heat exchanger) to be produced from or incorporating the brazing sheet 100. For example, in various non-limiting embodiments, the core layer 102 can have a first thickness t1, which can be in the range of 60% to 97% of the total thickness of the brazing sheet 100 (i.e., t 总 ). In various non-limiting embodiments, the brazing layer 104 can include a second thickness t2, which is in the range of 3% to 20% of the total thickness of the brazing sheet 100 (t 总 ). In various non-limiting embodiments, the first thickness t1 is greater than the second thickness t2. In certain non-limiting embodiments, the total thickness (t 总 ) of the brazing sheet 100 is in the range of 100 μm to 5 mm, e.g., in the range of 200 μm to 1 mm.

[0038] In various non-limiting embodiments, the brazing sheet according to the present disclosure can include one or more layers in addition to the core layer and the brazing layer. For example, referring to the non-limiting embodiment schematically shown in Figure 2 , the brazing sheet 200 includes a core layer 102, a brazing layer 104, and a layer 206, where the layer 206 is disposed on a second side 102b of the core layer 102 opposite to a first side 102a of the core layer 102 on which the brazing layer 104 is deposited. In various embodiments, the layer 206 can be a second brazing layer configured according to the brazing layer 104 described above, or the layer 206 can be a water side lining. In various non-limiting embodiments, the core layer 102, the brazing layer 104, and the layer 206 are joined (e.g., roll-bonded) together to form the brazing sheet 200.

[0039] In embodiments where the layer 206 is a second brazing layer, the layer 106 and the brazing layer 104 can have the same composition or can have different compositions.

[0040] In an embodiment where the water side liner is in layer 206, the water side liner can provide corrosion protection for the brazing sheet 200 and can contact the coolant during the operation of an article that includes all or a part of the brazing sheet 200. The water side liner can comprise a third aluminum alloy that comprises, by weight percent based on the total weight of the third aluminum alloy: 0.5 to 12 zinc; 0.1 to 1.2 silicon; 0 to 1 iron; 0 to 0.3 copper; 0 to 1.5 manganese; 0 to 0.6 magnesium; 0 to 0.2 titanium; 0 to 0.2 zirconium; optionally incidental elements; impurities; and aluminum.

[0041] In various non-limiting embodiments, the brazing sheet according to the present disclosure can include one or two interlayers. Referring to Figure 3 the non-limiting embodiment schematically shown in, the brazing sheet 300 includes a core layer 102, a brazing layer 104, a layer 206, an interlayer 308, and an interlayer 310. The interlayer 308 is intermediate the brazing layer 104 and the core layer 102, and the interlayer 310 is intermediate the layer 206 and the core layer 102. In various non-limiting embodiments, the core layer 102, the brazing layer 104, the layer 206, the interlayer 308, and the interlayer 310 are joined (e.g., roll-bonded) together to form the brazing sheet 300.

[0042] Each of the interlayers 308 and 310 of the brazing sheet 100 comprises a third aluminum alloy. The third aluminum alloy can comprise, by weight percent based on the total weight of the third aluminum alloy: 0.05 to 1.5 silicon; 0 to 2 manganese; 0 to 2 magnesium; 0 to 2 copper; 0 to 0.8 iron; 0 to 3 zinc; 0 to 0.5 zirconium; 0 to 1.0 chromium; 0 to 0.5 bismuth; 0 to 0.3 titanium; optionally incidental elements; impurities; and aluminum. The compositions of the interlayers 308 and 310 can be the same or different.

[0043] In various non-limiting embodiments, the brazing sheet according to the present disclosure can not include the interlayer 310, and the layer 206 can be in direct contact with the core layer 102. For example, referring to Figure 4 the non-limiting embodiment schematically shown in, the brazing sheet 400 includes a core layer 102, a brazing layer 104, a layer 206, and an interlayer 308. In various non-limiting embodiments, the core layer 102, the brazing layer 104, the layer 206, and the interlayer 308 are joined (e.g., roll-bonded) together to form the brazing sheet 400.

[0044] In various non-limiting embodiments, the brazing sheet according to the present disclosure can not include the interlayer 310 or the layer 206, and the core layer 102 can be exposed on one side. Referring to Figure 5In the non-limiting embodiments schematically shown, the brazing sheet 500 includes a core layer 102, a brazing layer 104, and an interlayer 308. In various non-limiting embodiments, the core layer 102, the brazing layer 104, and the interlayer 308 are joined (e.g., roll-bonded) together to form the brazing sheet 500.

[0045] The thickness of each layer in the brazing sheets 200, 300, 400, and 500 can be configured based on the desired structural properties of the article (e.g., heat exchanger) to be produced by or incorporating the brazing sheet 100. For example, in various non-limiting embodiments, the core layer 102 can have a first thickness t1, which can be in the range of 60% to 93% of the total thickness (i.e., t 总 ) of the respective brazing sheet 200, 300, 400, or 500. In various non-limiting embodiments, if present, the interlayer 308 and the interlayer 310 can have a third thickness t3 and t 3' , and the sum of these two thicknesses can be in the range of 3% to 30% of the total thickness (t 总 ) of the respective brazing sheet 200, 300, 400, or 500. In various non-limiting embodiments, the brazing layer 104 and the layer 206 can have a second thickness t2 and t 2′ , and the sum of these two thicknesses can be in the range of 3% to 20% of the total thickness (t 总 ) of the respective brazing sheet 200, 300, 400, or 500. In various non-limiting embodiments, the first thickness t1 is greater than each of the second thicknesses t2 and t2′, and is also greater than each of the third thicknesses t3 and t 3′ . In certain non-limiting embodiments, the total thickness (t 总 ) of the brazing sheet 200, 300, 400, or 500 is in the range of 100 μm to 5 mm, for example, in the range of 200 μm to 1 mm.

[0046] The brazing sheet 200 can be applicable to at least one of controlled atmosphere brazing and vacuum brazing. For example, the brazing sheet 200 can include a layer having a composition such that the brazing sheet 200 is suitable for controlled atmosphere brazing and / or vacuum brazing. In various non-limiting embodiments, where the brazing sheets 100, 200, 300, 400, and 500 can be brazed using a flux, according to the present disclosure, the diffusion of magnesium from the brazing sheet can be undesirable because it may interfere with the flux. In various non-limiting embodiments, the brazing sheet according to the present disclosure is configured to inhibit diffusion from the brazing sheet (e.g., inhibit the diffusion of magnesium) such that a flux can be used in the brazing process. In certain non-limiting embodiments, the brazing sheets 100, 200, 300, 400, and 500 according to the present disclosure can have a composition suitable for vacuum brazing (e.g., fluxless vacuum brazing). In various non-limiting embodiments, where the brazing sheets 100, 200, 300, 400, 500 are brazed without a flux (e.g., in a CAB furnace, without using any flux, brazed in an inert atmosphere containing residual O2), the diffusion of magnesium from the brazing sheet can be advantageous, for example, to dissolve the oxide layer formed on the brazing layer 104 and / or promote the wettability of the surface to be brazed.

[0047] In various non-limiting embodiments, an article (e.g., a heat exchanger) can include a structural element that includes all or a portion of the brazing sheets 100, 200, 300, 400, and / or 500. The galvanic corrosion resistance of the heat exchanger evaluated under ASTM G85 Appendix A3 (2019) can be at least 20 days, for example, at least 25 days or at least 30 days. The heat exchanger can be, for example, an oil cooler, a radiator, a cooling system (e.g., a battery cooling system), or a liquid-cooled condenser. In various non-limiting embodiments, the article can be tubular.

[0048] Figure 6 A block diagram of a non-limiting embodiment of a method according to the present disclosure for forming an article such as a heat exchanger is provided. The method embodiment includes contacting a first component that includes a first material with a second component that includes all or a portion of a non-limiting embodiment of the brazing sheet according to the present disclosure. For example, a non-limiting embodiment of the method according to the present disclosure can include contacting a first component that includes a first material with a second component that includes all or a portion of the brazing sheets 100, 200, 300, 400, 500 and / or a different embodiment of the brazing sheet according to the present disclosure ( Figure 4 , step 602). In various non-limiting embodiments, the first component can be brazed to the second component by a process that includes at least one of controlled atmosphere brazing and vacuum brazing ( Figure 6, step 604). In various non-limiting embodiments, the first material includes aluminum or an aluminum alloy.

[0049] The following numbered items are directed to various non-limiting embodiments and aspects in accordance with the present disclosure.

[0050] Item 1. A brazing sheet, the brazing sheet comprising:

[0051] A brazing layer comprising a 4XXX series aluminum alloy; and

[0052] A core layer comprising a first aluminum alloy, the first aluminum alloy comprising, based on the total weight of the first aluminum alloy in weight percent,

[0053] 0.2 to 0.6 silicon,

[0054] 1.5 to 2 manganese,

[0055] 0.01 to 0.2 titanium,

[0056] 0.5 to 2.5 copper,

[0057] 0 to 0.5 iron,

[0058] 0 to 0.5 magnesium,

[0059] 0 to 0.5 zinc,

[0060] 0 to 0.3 chromium,

[0061] 0 to 0.25 zirconium,

[0062] Optionally, incidental elements,

[0063] Impurities, and

[0064] aluminum,

[0065] wherein and [Mg], [Fe], [Cr], and [Si] are the weight percent concentrations of manganese, iron, chromium, and silicon, respectively, in the first aluminum alloy.

[0066] Item 2. The brazing sheet according to Item 1, wherein and [Mg], [Fe], [Cr], and [Si] are the weight percent concentrations of manganese, iron, chromium, and silicon, respectively, in the first aluminum alloy.

[0067] Item 3. The brazing sheet according to any one of Items 1 to 2, wherein the first aluminum alloy comprises, based on the total weight of the first aluminum alloy in weight percent:

[0068] 0.2 to 0.5 silicon;

[0069] 1.6 to 2 manganese;

[0070] 0.1 to 0.2 titanium;

[0071] 0.5 to 1 copper;

[0072] 0.1 to 0.4 iron;

[0073] 0 to 0.1 magnesium;

[0074] 0 to 0.25 zinc;

[0075] 0 to 0.3 chromium;

[0076] 0 to 0.25 zirconium;

[0077] Optionally incidental elements;

[0078] Impurities; and

[0079] Aluminum.

[0080] Clause 4. The brazing sheet according to any one of Clauses 1 to 3, wherein the first aluminum alloy comprises, by weight percentage based on the total weight of the first aluminum alloy:

[0081] 0.3 to 0.4 silicon;

[0082] 1.6 to 2 manganese;

[0083] 0.1 to 0.2 titanium;

[0084] 0.5 to 1 copper;

[0085] 0.1 to 0.4 iron;

[0086] 0 to 0.1 magnesium;

[0087] 0 to 0.25 zinc;

[0088] 0 to 0.3 chromium;

[0089] 0 to 0.25 zirconium;

[0090] Optionally incidental elements;

[0091] Impurities; and

[0092] Aluminum.

[0093] Clause 5. The brazing sheet according to any one of Clauses 1 to 4, wherein the weight ratio of copper to manganese in the first aluminum alloy is not greater than 1.

[0094] Clause 6. The brazing sheet according to any one of Clauses 1 to 5, wherein the core layer is inhomogeneous.

[0095] Clause 7. The brazing sheet according to any one of Clauses 1 to 6, wherein the 4XXX series aluminum alloy of the brazing layer contains, by weight percentage based on the total weight of the 4XXX series aluminum alloy:

[0096] 5 to 15 silicon;

[0097] 0 to 2 magnesium;

[0098] 0 to 1 iron;

[0099] 0 to 3 zinc;

[0100] 0 to 2 copper;

[0101] 0 to 1 manganese;

[0102] 0 to 0.3 bismuth;

[0103] Optionally, incidental elements;

[0104] Impurities; and

[0105] Aluminum.

[0106] Clause 8. The brazing sheet according to any one of Clauses 1 to 7, wherein the core layer and the brazing layer are joined together.

[0107] Clause 9. The brazing sheet according to any one of Clauses 1 to 8, the brazing sheet further comprising a water-side lining layer, wherein the core layer is between the water-side lining layer and the brazing layer.

[0108] Clause 10. The brazing sheet according to Clause 9, wherein the core layer, the water-side lining layer and the brazing layer are joined together.

[0109] Clause 11. The brazing sheet according to any one of Clauses 9 to 10, wherein the water-side lining layer comprises a third aluminum alloy, the third aluminum alloy containing, by weight percentage based on the total weight of the third aluminum alloy:

[0110] 0.5 to 12 zinc;

[0111] 0.1 to 1.2 silicon;

[0112] 0 to 1 iron;

[0113] 0 to 0.3 copper;

[0114] 0 to 1.5 manganese;

[0115] 0 to 0.6 magnesium;

[0116] 0 to 0.2 titanium;

[0117] 0 to 0.2 zirconium;

[0118] Optionally, incidental elements;

[0119] Impurities; and

[0120] Aluminum.

[0121] Clause 12. The brazing sheet according to any one of Clauses 1 to 8, wherein:

[0122] The brazing layer is a first brazing layer provided on a first side of the core layer; and

[0123] The brazing sheet further includes a second brazing layer provided on a second side of the core layer, the second side being opposite to the first side of the core layer, wherein the second brazing layer contains a 4XXX series aluminum alloy.

[0124] Clause 13. The brazing sheet according to Clause 12, wherein the core layer, the first brazing layer and the second brazing layer are joined together.

[0125] Clause 14. The brazing sheet according to Claim 12, the brazing sheet further includes a first interlayer, wherein the first interlayer is between the core layer and the first brazing layer.

[0126] Clause 15. The brazing sheet according to Clause 14, the brazing sheet further includes a second interlayer, wherein the second interlayer is between the core layer and the second brazing layer.

[0127] Clause 16. The brazing sheet according to any one of Clauses 1 to 11, the brazing sheet further includes an interlayer, wherein the interlayer is between the core layer and the brazing layer.

[0128] Clause 17. The brazing sheet according to any one of Clauses 1 to 16, wherein the brazing sheet has a composition suitable for at least one of controlled atmosphere brazing and vacuum brazing.

[0129] Clause 18. The brazing sheet according to Claim 1, wherein:

[0130] The core layer has a first thickness in the range of 60% to 97% of the total thickness of the brazing sheet; and

[0131] The brazing layer has a second thickness in the range of 3% to 20% of the total thickness of the brazing sheet.

[0132] Clause 19. The brazing sheet according to any one of Clauses 1 to 18, wherein the brazing sheet contains at least 30% of recycled materials.

[0133] Clause 20. An article, the article comprising or formed of components, the components including a structural element, the structural element comprising all or a portion of the brazing sheet according to any one of Clauses 1 to 19.

[0134] Clause 21. The article according to Clause 20, wherein the article is a tubular article.

[0135] Clause 22. The article according to any one of Clauses 20 to 21, wherein the article includes a heat exchanger.

[0136] Clause 23. The article according to Clause 22, wherein the article has a galvanic corrosion resistance of at least 20 days as evaluated according to ASTM G85 Appendix A3 (2019).

[0137] Clause 24. A method for forming a fabricated article, the method comprising:

[0138] bringing a first component comprising a first material into contact with a second component comprising all or a portion of the brazing sheet according to any one of Clauses 1 to 19; and

[0139] brazing the first component to the second component by a process comprising at least one of controlled atmosphere brazing and vacuum brazing.

[0140] Clause 25. The method according to Clause 24, wherein the first material comprises aluminum or an aluminum alloy.

[0141] Clause 26. The method according to Claim 23, wherein the article is a heat exchanger.

[0142] Clause 27. The brazing sheet according to any one of Clauses 1 to 19, wherein the first aluminum alloy comprises, by weight percent based on the total weight of the first aluminum alloy:

[0143] 0.2 to 0.5 silicon;

[0144] 1.6 to 2 manganese;

[0145] 0.01 to 0.2 titanium;

[0146] 0.5 to 1 copper;

[0147] 0.1 to 0.4 iron;

[0148] 0 to 0.1 magnesium;

[0149] 0 to 0.25 zinc;

[0150] 0 to 0.3 chromium;

[0151] 0 to 0.25 zirconium;

[0152] Optionally, incidental elements;

[0153] Impurities; and

[0154] Aluminum.

[0155] Clause 28. The brazing sheet according to any one of Clauses 1 to 19, wherein the first aluminum alloy comprises, by weight percentage based on the total weight of the first aluminum alloy:

[0156] 0.3 to 0.4 silicon;

[0157] 1.6 to 2 manganese;

[0158] 0.01 to 0.2 titanium;

[0159] 0.5 to 1 copper;

[0160] 0.1 to 0.4 iron;

[0161] 0 to 0.1 magnesium;

[0162] 0 to 0.25 zinc;

[0163] 0 to 0.3 chromium;

[0164] 0 to 0.25 zirconium;

[0165] Optionally, incidental elements;

[0166] Impurities; and

[0167] Aluminum.

[0168] Clause 29. A brazing sheet, the brazing sheet comprising:

[0169] A brazing layer comprising a 4XXX series aluminum alloy; and

[0170] A core layer comprising a first aluminum alloy, the first aluminum alloy comprising, by weight percentage based on the total weight of the first aluminum alloy,

[0171] 0.2 to 0.6 silicon,

[0172] 1.5 to 2 manganese, wherein the weight ratio of manganese to silicon in the first aluminum alloy is at least 3.1,

[0173] 0.1 to 0.2 titanium,

[0174] 0.5 to 2.5 copper,

[0175] 0 to 0.5 iron,

[0176] 0 to 0.5 magnesium,

[0177] zinc from 0 to 0.5,

[0178] chromium from 0 to 0.3,

[0179] zirconium from 0 to 0.25,

[0180] optionally incidental elements,

[0181] impurities, and

[0182] aluminum.

[0183] Clause 30. A brazing sheet, the brazing sheet comprising:

[0184] a brazing layer comprising a 4XXX series aluminum alloy; and

[0185] a core layer comprising a first aluminum alloy, the first aluminum alloy comprising, based on the total weight of the first aluminum alloy in weight percentage,

[0186] silicon from 0.2 to 0.6,

[0187] manganese from 1.5 to 2, wherein the weight ratio of manganese to silicon in the first aluminum alloy is at least 3.1,

[0188] titanium from 0.01 to 0.2,

[0189] copper from 0.5 to 2.5,

[0190] iron from 0 to 0.5,

[0191] magnesium from 0 to 0.5,

[0192] zinc from 0 to 0.5,

[0193] chromium from 0 to 0.3,

[0194] zirconium from 0 to 0.25,

[0195] optionally incidental elements,

[0196] impurities, and

[0197] aluminum.

[0198] In this specification, unless otherwise indicated, all numerical parameters should be understood to be prefaced and modified in all instances by the term "about", where the numerical parameters have the inherent variability characteristics of the underlying measurement techniques used to determine the numerical values of the parameters. At the very least, and without attempting to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter described herein should be construed at least in accordance with the number of significant digits reported and by applying ordinary rounding techniques.

[0199] In addition, any numerical range recited herein includes all sub-ranges subsumed within the recited range. For example, the range "1 to 10" includes all sub-ranges between (and including) the recited minimum value 1 and the recited maximum value 10, i.e., the minimum value is equal to or greater than 1, and the maximum value is equal to or less than 10. Moreover, all ranges recited herein include the endpoints of the recited range. For example, the range "1 to 10" includes the endpoints 1 and 10. Any maximum numerical limitation recited in this specification is intended to include all lower numerical limitations subsumed therein, and any minimum numerical limitation recited in this specification is intended to include all higher numerical limitations subsumed therein. Accordingly, the applicant reserves the right to modify this specification (including the claims) to expressly recite any sub-range subsumed within the ranges expressly recited herein. All such ranges are inherently described in this specification.

[0200] Unless otherwise indicated, the grammatical articles "a", "an", and "the" as used herein are intended to include "at least one" or "one or more", even if in some instances "at least one" or "one or more" is expressly used. Thus, the foregoing grammatical articles are used herein to refer to one or more than one (i.e., "at least one") particular identified element. In addition, the use of a singular noun includes the plural, and the use of a plural noun includes the singular, unless the context of use otherwise requires.

[0201] Those skilled in the art will recognize that, for the sake of conceptual clarity, the articles and methods described herein, and their accompanying discussion, are used as examples, and various configuration modifications are contemplated. Thus, as used herein, the specific examples / embodiments set forth and the accompanying discussion are intended to represent their more general classes. Generally, the use of any particular example is intended to represent its class, and the absence of a particular component, device, operation / action, and object should not be regarded as restrictive. While this disclosure provides a description of various specific aspects for purposes of illustrating aspects of the disclosure and / or its potential applications, it is to be understood that those skilled in the art will envision variations and modifications. Accordingly, one or more of the inventions described herein should be understood to be at least as broad as the claims to be protected, and not more narrowly defined than the specific illustrative aspects provided herein.

Claims

1. A brazing sheet, the brazing sheet comprising: A brazing layer, the brazing layer comprising a 4XXX series aluminum alloy; and A core layer, the core layer comprising a first aluminum alloy, the first aluminum alloy comprising, based on the total weight of the first aluminum alloy in weight percentage: 0.2 to 0.6 of silicon, 1.5 to 2 of manganese, 0.01 to 0.2 titanium, 0.5 to 2.5 copper, 0 to 0.5 iron, 0 to 0.5 magnesium, 0 to 0.5 zinc, 0 to 0.3 chromium, 0 to 0.25 zirconium, optionally incidental elements, impurities, and aluminum, wherein and [Mg], [Fe], [Cr] and [Si] are the weight percentage concentrations of manganese, iron, chromium and silicon in the first aluminum alloy, respectively.

2. The brazing sheet according to claim 1, wherein And [Mg], [Fe], [Cr], and [Si] are the weight percentage concentrations of manganese, iron, chromium, and silicon in the first aluminum alloy, respectively.

3. The brazing sheet according to claim 1, wherein the first aluminum alloy comprises, based on the total weight of the first aluminum alloy in weight percentage: 0.2 to 0.5 of silicon; 1.6 to 2 manganese; 0.1 to 0.2 titanium; 0.5 to 1 copper; 0.1 to 0.4 iron; 0 to 0.1 magnesium; 0 to 0.25 zinc; 0 to 0.3 chromium; 0 to 0.25 zirconium; optionally incidental elements; impurities; and aluminum.

4. The brazing sheet according to claim 1, wherein the first aluminum alloy comprises, based on the total weight of the first aluminum alloy in weight percentage: 0.3 to 0.4 of silicon; 1.6 to 2 manganese; 0.1 to 0.2 titanium; 0.5 to 1 copper; 0.1 to 0.4 iron; 0 to 0.1 magnesium; 0 to 0.25 zinc; 0 to 0.3 chromium; 0 to 0.25 zirconium; optionally incidental elements; impurities; and aluminum.

5. The brazing sheet according to claim 1, wherein the weight ratio of copper to manganese in the first aluminum alloy is not greater than 1.

6. The brazing sheet according to claim 1, wherein the core layer is non - homogeneous.

7. The brazing sheet according to claim 1, wherein the 4XXX series aluminum alloy of the brazing layer comprises, by weight percentage based on the total weight of the 4XXX series aluminum alloy: 5 to 15 silicon; 0 to 2 magnesium; 0 to 1 iron; 0 to 3 zinc; 0 to 2 copper; 0 to 1 manganese; 0 to 0.3 bismuth; optionally incidental elements; impurities; and aluminum.

8. The brazing sheet according to claim 1, wherein the core layer and the brazing layer are joined together.

9. The brazing sheet according to claim 1, the brazing sheet further comprises a water - side lining layer, wherein the core layer is between the water - side lining layer and the brazing layer.

10. The brazing sheet according to claim 9, wherein the core layer, the water - side lining layer and the brazing layer are joined together.

11. The brazing sheet according to claim 9, wherein the water - side lining layer comprises a third aluminum alloy, the third aluminum alloy comprising, by weight percentage based on the total weight of the third aluminum alloy: 0.5 to 12 zinc; Silicon from 0.1 to 1.2; 0 to 1 iron; 0 to 0.3 copper; 0 to 1.5 manganese; 0 to 0.6 magnesium; 0 to 0.2 titanium; 0 to 0.2 zirconium; optionally incidental elements; impurities; and aluminum.

12. The brazing sheet according to claim 1, wherein: The brazing layer is a first brazing layer provided on a first side of the core layer; and The brazing sheet further includes a second brazing layer provided on a second side of the core layer, the second side being opposite to the first side of the core layer, wherein the second brazing layer contains a 4XXX series aluminum alloy.

13. The brazing sheet according to claim 12, wherein the core layer, the first brazing layer, and the second brazing layer are joined together.

14. The brazing sheet according to claim 12, wherein the brazing sheet further comprises a first interlayer, and the first interlayer is between the core layer and the first brazing layer.

15. The brazing sheet according to claim 14, wherein the brazing sheet further comprises a second interlayer, and the second interlayer is between the core layer and the second brazing layer.

16. The brazing sheet according to claim 1, wherein the brazing sheet further comprises an interlayer, and the interlayer is between the core layer and the brazing layer.

17. The brazing sheet according to claim 1, wherein the brazing sheet has a composition suitable for at least one of controlled atmosphere brazing and vacuum brazing.

18. The brazing sheet according to claim 1, wherein: The core layer has a first thickness in the range of 60% to 97% of the total thickness of the brazing sheet; and the brazing layer has a second thickness in the range of 3% to 20% of the total thickness of the brazing sheet.

19. The brazing sheet according to claim 1, wherein the brazing sheet contains at least 30% of waste materials.

20. An article, the article comprising or formed from components, the components comprising a structural element, the structural element comprising all or a part of the brazing sheet according to claim 1.

21. The article according to claim 20, wherein the article is a tubular article.

22. The article according to claim 20, wherein the article comprises a heat exchanger.

23. The article according to claim 22, wherein the article has a galvanic corrosion resistance of at least 20 days as evaluated according to ASTM G85 Appendix A3 (2019).

24. A method for forming a fabricated article, the method comprising: Bring a first component containing a first material into contact with a second component containing all or part of the brazing sheet according to claim 1; and Brazing the first component to the second component by a process including at least one of controlled atmosphere brazing and vacuum brazing.

25. The method according to claim 24, wherein the first material comprises aluminum or an aluminum alloy.

26. The method according to claim 24, wherein the article is a heat exchanger.

Images