Material braze coating and welding integrated device and method under atmosphere protection

Abstract

The invention discloses a material braze coating and welding integrated device and method under atmosphere protection, and relates to the technical field of material connection. The device comprises an atmosphere protection assembly, a welding flux supply assembly, an ultrasonic coating assembly, a welding assembly and a controller. A spray head of the ultrasonic coating assembly is connected with an ultrasonic tool head and arranged between the upper base metal and the lower base metal, and tiny gaps are kept between the spray head and the base metal. Under the protective atmosphere, the welding flux supply assembly conveys liquid welding flux to the spray head to enable the liquid welding flux to overflow, the ultrasonic tool head applies ultrasonic vibration to the welding flux attached to the surface of the spray head, and the welding flux forms brazing coating layers on the surfaces of the upper base metal and the lower base metal at the same time. And after coating is completed, the welding assembly drives the base metal to move so that the spray head can move out of the weld joint area, and pressure welding is conducted on the base metal. According to the method, braze coating and welding are continuously completed under the protective atmosphere, oxidation of active elements is avoided, the ultrasonic energy utilization rate is increased, damage of ultrasonic vibration to brittle base metal is avoided, and the method is suitable for high-reliability connection between ceramic and metal or between ceramic and ceramic.

Description

Technical Field

[0001] This invention relates to the field of material joining technology, and more specifically, to an apparatus and method for achieving integrated brazing and welding of material surfaces under a protective atmosphere. Background Technology

[0002] Ceramic-metal connectors possess the advantages of ceramics (high temperature resistance, corrosion resistance, and high hardness) and metals (good thermal and electrical conductivity and machinability), making them promising for applications in aerospace, electronic packaging, nuclear energy, and medical devices. However, ceramics and metals differ significantly in their physicochemical properties. For example, ceramics typically have high melting points, low coefficients of thermal expansion, and ionic or covalent bond structures, while metals have metallic bond structures. This makes it difficult to achieve reliable connections between the two using traditional fusion welding methods.

[0003] Currently, one of the mainstream technologies for joining ceramics and metals is ultrasonic-assisted active brazing. This technology utilizes the active elements (such as Ti and Zr) in the active brazing filler metal to react chemically with the ceramic surface, forming a reaction layer, thereby achieving wetting and bonding between the ceramic and the metal. Simultaneously, the cavitation effect generated by the introduced ultrasonic vibration in the liquid brazing filler metal can break up the oxide film on the ceramic surface, promoting filler metal filling and interfacial reactions, further improving the bonding quality.

[0004] However, existing ultrasonic-assisted active brazing processes face the following technical bottlenecks in practical applications: First, elements such as Ti and Zr in the active brazing filler metal are extremely chemically reactive at high temperatures, readily reacting with oxygen and nitrogen in the air to form oxides or nitrides. This not only consumes the active elements, rendering them unable to react with the ceramic, but also forms brittle inclusions in the brazing seam, severely deteriorating the joint's mechanical properties. Traditionally, welding is performed in a vacuum or protective atmosphere, but if the process requires transferring the workpiece or performing step-by-step operations, oxidation is inevitable. Second, ultrasonic energy utilization is low and it easily damages the base material. In conventional ultrasonic-assisted brazing processes, ultrasonic vibration is typically applied to the bottom of the base material, transmitting the ultrasonic energy to the brazing seam area through the base material. This indirect application method leads to severe attenuation of ultrasonic energy as it propagates within the base material, especially for brittle materials like ceramics, where the attenuation is even more significant, resulting in low energy utilization. Simultaneously, prolonged ultrasonic vibration directly acts on the brittle ceramic base material, easily inducing microcracks or even macroscopic cracking within the base material, causing irreversible mechanical damage and reducing product yield. Third, the process continuity is poor. Although there is a step-by-step method that involves ultrasonically dipping an active brazing filler layer onto the base material before assembly and welding, attempting to avoid direct damage to the base material from ultrasonic vibration, this method requires transferring workpieces between different equipment or workstations. During the transfer, the coated surface exposed to air is highly susceptible to oxidation, and this increases process turnaround time, reduces production efficiency, and makes it difficult to achieve high-quality, high-efficiency continuous production.

[0005] Therefore, there is an urgent need to develop a novel integrated brazing and welding device and method that can effectively prevent the oxidation of active elements, improve the utilization rate of ultrasonic energy, protect brittle base materials, and achieve continuous production. Summary of the Invention

[0006] To address the problems of easy oxidation of active elements, low ultrasonic energy utilization and easy damage to the base material, and poor process continuity in existing technologies, this invention provides an integrated device and method that can continuously complete brazing and welding under a protective atmosphere, thereby improving ultrasonic energy utilization, avoiding damage to the base material, and preventing oxidation of active elements.

[0007] To achieve the above objectives, the specific solution adopted by the present invention is as follows: In a first aspect, the present invention provides an integrated apparatus for brazing and welding materials under a protective atmosphere, comprising: Atmosphere protection components are used to provide a protective atmosphere; Solder supply assembly for storing and conveying liquid solder; An ultrasonic coating assembly includes an ultrasonic tool head and a nozzle connected to the ultrasonic tool head. The nozzle is connected to the solder supply assembly and is used to receive liquid solder and allow the liquid solder to overflow. A welding assembly for clamping and moving a first and second base material disposed opposite to each other; The controller is used to control the above components; The nozzle is disposed between the first base material and the second base material, and maintains a gap with both of them; The ultrasonic coating assembly is used to apply ultrasonic vibration to liquid solder that overflows and adheres to the nozzle surface and is in contact with two base materials simultaneously under the protective atmosphere, so that the liquid solder simultaneously forms a brazing coating on the opposing surfaces of the first base material and the second base material. The welding assembly is used to move the base material after coating is completed so that the nozzle moves out between the first base material and the second base material, and to weld the two materials with the brazing coating formed thereon to the first heater; the welding assembly includes a top mechanical claw for clamping and heating the first base material and a bottom mechanical claw for carrying and heating the second base material, the top mechanical claw is provided with a second heater, and the bottom mechanical claw is provided with a third heater.

[0008] Furthermore, the ultrasonic coating assembly also includes an ultrasonic transducer and an amplitude transformer. The ultrasonic transducer is connected to the ultrasonic tool head via the amplitude transformer. The amplitude transformer has a cooling water inlet and a cooling water outlet for cooling and protecting the ultrasonic transducer.

[0009] Furthermore, the solder supply assembly includes a first gas source, a storage tank, and a conveying channel; the first gas source is connected to the storage tank through a pipeline equipped with a flow controller, for introducing gas into the storage tank to generate air pressure; the storage tank is connected to the nozzle through the conveying channel, and under the drive of the air pressure, liquid solder is conveyed to the nozzle through the conveying channel; the storage tank is equipped with a pressure relief valve.

[0010] Furthermore, the ultrasonic tool head is coaxially connected to the nozzle, and the nozzle has a hollow structure with multiple nozzle holes communicating with its interior on the surface opposite to the first and second base materials.

[0011] Furthermore, the diameter of the nozzle is 0.2–1 mm; the inner wall of the material conveying channel and the inner and outer surfaces of the nozzle are all treated with corrosion-resistant reinforcement.

[0012] Furthermore, the atmosphere protection component includes a second gas source, a gas pipeline, and a fourth heater disposed on the gas pipeline. One end of the gas pipeline is connected to the second gas source, and the other end faces the area where the nozzle and the base material are located.

[0013] Secondly, the present invention provides a method for integrating material brazing and welding using the above-mentioned apparatus, comprising the following steps: S1: Place the nozzle between the first and second base materials that are positioned opposite each other, and maintain a gap of 0.5 to 1 mm between the nozzle and both. S2: Under a protective atmosphere, liquid solder is delivered to the nozzle, causing it to overflow and adhere to the nozzle surface, and simultaneously contact the two base materials; ultrasonic vibration is applied to the liquid solder adhering to the nozzle surface, causing the liquid solder to simultaneously form a brazing coating on the opposing surfaces of the first and second base materials. S3: Move the nozzle out of the area between the first base material and the second base material; S4: Pressure welding is performed on the first and second base materials with brazing coatings to complete the connection.

[0014] Furthermore, in S2, the amplitude of the ultrasonic vibration is 2–10 μm, the frequency is 15–100 kHz, and the application time is 1–10 seconds.

[0015] Furthermore, in S4, after welding is completed, the weldment is cooled to below 100°C at a cooling rate not exceeding 10°C / min.

[0016] Compared with the prior art, the present invention has the following beneficial effects: (1) The present invention completes the two core processes of brazing and welding continuously in the same protective atmosphere. From the delivery and application of liquid solder to the final welding, the workpiece is always in a protective atmosphere, which completely eliminates the possibility of active elements being oxidized by contact with air during the process transfer or waiting, thereby ensuring the accuracy of the solder composition and the interfacial reaction activity, laying the foundation for obtaining high-quality joints.

[0017] (2) The core of this invention lies in placing the nozzle directly within the tiny gap between the upper and lower base materials. Ultrasonic vibration is applied directly to the liquid solder overflowing from the nozzle surface and in contact with the two base materials via the ultrasonic tool head, rather than being indirectly transmitted through the base materials. This "near-field" ultrasonic action mode allows ultrasonic energy to act on the liquid solder with almost no attenuation, resulting in extremely high energy utilization and significant interface activation. More importantly, the ultrasonic tool head does not directly contact the brittle ceramic base material, fundamentally eliminating the risk of mechanical damage to the base material caused by ultrasonic vibration, making it particularly suitable for joining brittle materials such as ceramics.

[0018] (3) The device of the present invention integrates functional modules such as solder supply, ultrasonic coating, atmosphere protection, and welding into one unit, and coordinates and controls them through a controller. After coating is completed, the nozzle can be removed from the weld area by moving the base material through the welding component, and then pressure welding can be performed directly. The whole process is seamless. This integrated design not only simplifies the process flow and shortens the production cycle, but also makes it easy to realize assembly line operation. Subsequent workpieces can continuously enter the station for coating and welding, which greatly improves production efficiency.

[0019] (4) The protective gas, heated by the fourth heater, is sprayed onto the nozzle and welding area. While providing gas protection for coating, it also heats the nozzle to ensure that the internal solder remains liquid and prevents it from solidifying and clogging the nozzle. Simultaneously, the solder supply assembly is pneumatically driven, and the gas pressure and flow rate are precisely controlled by a flow controller, thereby achieving precise control over the amount of solder overflow. Furthermore, the use of multiple heaters (the first heater for melting the solder, the second and third heaters for preheating and temperature control of the base material, and the fourth heater for heating the protective gas) ensures precise control of the temperature field throughout the process, guaranteeing the stability of coating and welding quality. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the overall structure of the integrated brazing and welding device for materials under atmosphere protection in an embodiment of the present invention.

[0021] Figure 2 for Figure 1 A magnified view of the area where the coating was applied.

[0022] Figure 3 This is a schematic diagram of the nozzle structure in this invention.

[0023] Figure 4 This is a cross-sectional view of the nozzle in this invention.

[0024] Figure 5 This is a photograph of the actual SiC ceramic and Cu metal connector in an embodiment of the present invention.

[0025] In the diagram: 1. Controller; 2. Ultrasonic coating assembly; 21. Ultrasonic transducer; 22. Amplitude bar; 23. Ultrasonic tool head; 24. Cooling water outlet; 25. Cooling water inlet; 26. Nozzle; 261. Nozzle; 3. Solder supply assembly; 31. First air source; 32. Flow controller; 33. Storage tank; 34. Pressure relief valve; 35. Material conveying channel; 36. First heater; 4. Welding assembly; 41. Robotic arm; 42. Top robotic gripper; 43. Second heater; 44. Third heater; 45. Bottom robotic gripper; 5. Atmosphere protection assembly; 51. Second air source; 52. Gas flow meter; 53. Gas pipeline; 54. Fourth heater; 6. Base material to be welded; 61. First base material; 62. Second base material. Detailed Implementation

[0026] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings and specific embodiments. Obviously, the described embodiments are merely some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0027] It should be noted that in the description of this invention, the terms "first", "second", "third" and "fourth" are used only to distinguish different components or features and do not indicate any order, quantity or importance.

[0028] Please see Figures 1 to 4 This invention provides an integrated device for brazing and welding materials under a protective atmosphere. The device includes a controller 1, an ultrasonic coating component 2, a solder supply component 3, a welding component 4, a protective atmosphere component 5, and a base material 6 to be welded. The controller 1 serves as the central control system of the entire device, electrically connected to each component, and is used to coordinate and control the actions, temperature, pressure, ultrasonic parameters, etc., of each component.

[0029] The ultrasonic coating assembly 2 includes an ultrasonic transducer 21, an amplitude transformer 22, an ultrasonic tool head 23, and a nozzle 26. The ultrasonic transducer 21 is fixed to the device frame and is tightly connected to one end of the amplitude transformer 22 by bolts, used to convert electrical energy into ultrasonic frequency mechanical vibration. The amplitude transformer 22 amplifies the amplitude generated by the ultrasonic transducer 21 and transmits it to the ultrasonic tool head 23. The amplitude transformer 22 has a cooling water inlet 25 and a cooling water outlet 24, used to circulate cooling water during equipment operation to remove the heat generated by the ultrasonic transducer 21, providing cooling protection and ensuring its long-term stable operation. One end of the ultrasonic tool head 23 is bolted to the other end of the amplitude transformer 22, and its free end is coaxially connected to the nozzle 26. The nozzle 26 is connected to the ultrasonic tool head 23, allowing the ultrasonic vibration of the ultrasonic tool head 23 to be directly transmitted to the nozzle 26. It should be noted that the ultrasonic tool head 23 only needs to ensure that the nozzle 26 can be inserted between the upper and lower base materials; it does not need to enter the gap between the base materials themselves. The amplitude transformer 22 and the ultrasonic tool head 23 are preferably made of aluminum alloy, titanium alloy, or tungsten alloy, as these materials have good ultrasonic conduction and heat resistance properties.

[0030] like Figure 3 and Figure 4 As shown, the nozzle 26 has a hollow structure, and its internal channel is connected to the material conveying channel 35, which will be described later. Multiple nozzle holes 261 communicating with the interior are formed on the surfaces of the nozzle 26 opposite to the first base material 61 and the second base material 62 (i.e., the upper and lower surfaces). The diameter of the nozzle holes 261 is designed to be 0.2–1 mm. This size range ensures that the liquid solder overflows uniformly under pressure, forming a uniform liquid film, while preventing the liquid solder from overflowing without pressure.

[0031] The ultrasonic tool head 23 of the ultrasonic coating assembly 2 can adjust the amplitude in the range of 2 to 10 μm and the frequency in the range of 15 to 100 kHz during operation to adapt to different material and process requirements.

[0032] The solder supply assembly 3 is used to store, melt, and deliver liquid solder to the nozzle 26. It includes a first gas source 31, a flow controller 32, a storage tank 33, a pressure relief valve 34, a conveying channel 35, and a first heater 36. The first gas source 31 is a high-pressure argon cylinder, providing the inert gas pressure required to drive the solder. The first gas source 31 is connected to the upper part of the storage tank 33 via a pipeline equipped with the flow controller 32, which precisely controls and regulates the gas pressure and flow rate entering the storage tank 33, thereby controlling the extrusion speed and quantity of the liquid solder. The storage tank 33 holds the solid solder, and its side wall or bottom is equipped with a first heater 36 (e.g., a heating coil) to heat the solder, melting it and maintaining it in a liquid state. The heating temperature of the first heater 36 is typically set above the solder melting point by 100°C to ensure good solder flowability. A pressure relief valve 34 is also provided at the top of the storage tank 33 to automatically release pressure when the internal pressure is too high, ensuring system safety. The lower part of the storage tank 33 is vertically connected to the interior of the nozzle 26 through the conveying channel 35. During operation, the air pressure provided by the first air source 31 drives the liquid solder in the storage tank 33 to be conveyed through the conveying channel 35 and finally delivered to the nozzle 26.

[0033] To further prevent the materials of the nozzle 26 and the feed channel 35 from dissolving in the liquid solder at high temperatures, the inner surface of the feed channel 35 and the inner and outer surfaces of the nozzle 26 can be treated with a solder-contact surface corrosion-resistant strengthening treatment to improve their resistance to melting. This treatment method is a preferred option and can be selected according to actual needs. This corrosion-resistant layer has high chemical stability and can effectively block direct contact between the liquid solder and the base material, thereby inhibiting the dissolution of the base material (such as aluminum alloy, titanium alloy, etc.) into the liquid solder. Experiments show that the nozzle treated with the solder-contact surface corrosion-resistant strengthening treatment showed no obvious corrosion marks on its surface after 8 hours of continuous operation, while the untreated control showed obvious material dissolution and solder contamination after only 2 hours.

[0034] Welding assembly 4 is used for clamping, heating, moving the base material, and applying pressure during the welding stage. It includes a robotic arm 41, a top robotic gripper 42, a second heater 43, a third heater 44, and a bottom robotic gripper 45. The robotic arm 41 can drive the top robotic gripper 42 to move in three-dimensional space to clamp the first base material 61, adjust the gap, horizontally shift it, and apply welding pressure. The top robotic gripper 42 is used to clamp the first base material 61 and has a second heater 43 mounted on it. The second heater 43 is preferably embedded inside the clamping surface of the top robotic gripper 42 that contacts the first base material 61 or embedded inside the body of the top robotic gripper 42. It is used to preheat, maintain the temperature of the first base material 61 through heat conduction, control the temperature during the welding process, and slowly cool it after welding. The bottom mechanical claw 45 is used to support and fix the second base material 62. A third heater 44 is mounted on it, preferably embedded inside the bearing surface of the bottom mechanical claw 45 where it contacts the second base material 62, or embedded inside the body of the bottom mechanical claw 45, for heating and temperature control of the second base material 62. The bottom mechanical claw 45 is also connected to another mechanical arm 41 (not shown in the figure). Integrating the heater near the clamping or bearing surface of the mechanical claw enables a "clamping and heating simultaneously" function, allowing the base material to be preheated and temperature controlled during clamping and fixing, eliminating the need for an additional independent heating device and resulting in a more compact structure. Furthermore, the welding assembly 4 also has horizontal conveying capabilities. The mechanical arm 41 can simultaneously move the upper and lower base materials horizontally to achieve continuous coating and remove the nozzle 26 from the weld area. It should be noted that the specific structures of the top mechanical claw 42 and the bottom mechanical claw 45 are prior art, and their specific structures will not be described in detail in this invention.

[0035] Displacement sensors or laser rangefinders (not shown in the figure) can be integrated on the robotic arm 41, the top robotic gripper 42, and the bottom robotic gripper 45 to monitor the gap between the nozzle 26 and the upper and lower substrates in real time. The controller 1 adjusts the position of the robotic arm 41 in real time according to the sensor feedback signals to compensate for gap changes caused by thermal expansion or vibration, ensuring that the gap remains stable within the preset range during the coating process.

[0036] The atmosphere protection component 5 provides a stable and clean protective atmosphere throughout the brazing and welding process, preventing oxidation of active elements. It includes a second gas source 51, a gas flow meter 52, a gas pipeline 53, and a fourth heater 54. The second gas source 51 is a high-pressure argon cylinder that provides the protective gas. One end of the gas pipeline 53 is connected to the second gas source 51, and the other end opens towards the nozzle 26 and the welding area where the base material is located. The gas pipeline 53 is equipped with the gas flow meter 52 and the fourth heater 54 sequentially. The gas flow meter 52 monitors and regulates the flow rate of the protective gas. The fourth heater 54 heats the protective gas flowing through the gas pipeline 53 to a preset temperature. The heated protective gas is sprayed onto the nozzle 26 and the area where the base material is located, providing gas protection for coating and welding while simultaneously providing auxiliary heating to the nozzle 26 to prevent the liquid solder inside the nozzle 26 from solidifying and clogging due to heat loss, thus ensuring process stability. The heating temperature of the fourth heater 54 can be adjusted according to the melting point of the solder and the preheating temperature of the base material. It is usually set to be close to or slightly higher than the preheating temperature of the base material to avoid the cold airflow causing a drop in temperature to the welding area. The gas flow rate is controlled within the range of 0.5 to 5 L / min by the gas flow meter 52 to ensure effective air removal while avoiding excessive airflow that could disturb the liquid solder.

[0037] The base material 6 to be soldered includes a first base material 61 and a second base material 62 arranged opposite to each other. During the coating stage, the nozzle 26 is precisely positioned between the first base material 61 and the second base material 62, with its upper and lower surfaces maintaining a small gap with the opposing surfaces of the upper and lower base materials. This gap is preferably 0.5 to 1 mm. This gap range ensures that the liquid solder can smoothly contact and spread onto the surface of the base material under ultrasonic action, while also ensuring the efficient use of ultrasonic energy.

[0038] The following describes in detail, in conjunction with the above-described device structure, the method for integrating material brazing and welding using the device of the present invention.

[0039] Taking SiC ceramic as the first base material 61, Cu metal as the second base material 62, and Sn-Ag-Ti active solder as the solder as an example, the method includes the following steps: Step 1: Base Material Clamping and Gap Adjustment: Place the second base material 62 on the bottom mechanical gripper 45 and fix it in place. Fix the first base material 61 on the top mechanical gripper 42. Control the robotic arm 41 via controller 1 to precisely adjust the gap between the lower surface of the first base material 61 and the upper surface of the nozzle 26 to a preset value. This preset value can be selected within the range of 0.5 to 1 mm, for example, 0.5 mm or 0.8 mm. Since the bottom mechanical gripper 45 is fixed in position, the gap between the lower surface of the nozzle 26 and the upper surface of the second base material 62 is also this preset value. During this process, a displacement sensor or laser rangefinder monitors the gap value in real time and feeds it back to controller 1 to ensure accurate and stable gap. Step 2: Activate Atmosphere Protection and Preheating: Activate the atmosphere protection component 5. Open the second gas source 51, and the protective gas (argon) flows out through the gas pipeline 53. The gas flow meter 52 controls the flow rate, for example, within the range of 1-5 L / min. Simultaneously, activate the fourth heater 54 to heat the argon to a preset temperature, for example, 260℃. The heated argon is continuously blown towards the nozzle 26 and the area where the base material is located, establishing a stable inert gas protective atmosphere and preheating the nozzle 26 and the base material. Step 3, Base Material Heating: Start the second heater 43 and the third heater 44 to heat the first base material 61 and the second base material 62 to the preset temperature, such as 260°C, respectively, to prepare for subsequent solder wetting and spreading; Step 4: Solder Melting and Delivery: The first heater 36 in the storage tank 33 is activated to heat the Sn-Ag-Ti active solder to a temperature 100°C above its melting point, for example, 320°C, until it is completely melted. The first gas source 31 is turned on, and the argon gas pressure is adjusted to a preset value, for example, 0.2 MPa, via the flow controller 32. Under this pressure, the liquid solder is delivered through the delivery channel 35 to the nozzle 26. Simultaneously, the cooling water system is activated to cool and protect the ultrasonic transducer 21. Step 5, Ultrasonic-Assisted Brazing: Activate the ultrasonic coating assembly 2 and set the amplitude (within the range of 2–10 μm, e.g., 5 μm) and frequency (within the range of 15–100 kHz, e.g., 20 kHz) according to process requirements. Under air pressure, liquid solder slowly overflows from the nozzles 261 on the upper and lower surfaces of the nozzle 26, adhering to the surface of the nozzle 26 and contacting the two base materials. At this time, ultrasonic vibration is applied to the liquid solder adhering to the surface of the nozzle 26. The resulting cavitation effect promotes the reaction of active elements in the solder on the SiC surface, thereby achieving effective wetting of the liquid solder on the SiC ceramic surface. Furthermore, the number and distribution of the nozzles 261 on the upper and lower surfaces of the nozzle 26 can be symmetrically arranged to further ensure a uniform brazing coating on the upper and lower base material surfaces. Experiments show that within the amplitude range of 2–10 μm and the frequency range of 15–100 kHz, the solder can achieve good bidirectional spreading. The ultrasonic treatment time can be selected within the range of 1–10 seconds according to the coating area and solder characteristics. If the area to be welded is long, the upper and lower base materials can be moved forward at a uniform speed in the horizontal direction by the robotic arm 41 of the welding component 4. The coating length can be controlled by controlling the moving distance, and the brazing rate can be adjusted in the range of 1 to 10 mm / s. Step Six: Remove the nozzle: After coating is completed, stop the ultrasonic treatment. The robotic arm 41 of the welding assembly 4 moves the upper and lower base materials forward, completely removing the nozzle 26 from the weld area between the first base material 61 and the second base material 62. Before the nozzle 26 is removed, the ultrasonic treatment has stopped, and the liquid solder has spread and partially wetted the base material surface. At this point, the interfacial bonding force between the solder and the base material is greater than the adhesion force between the solder and the nozzle surface. Therefore, when the welding assembly 4 moves the base material horizontally, the nozzle 26 can easily separate from the base material without damaging the formed brazing coating. Furthermore, the erosion-resistant strengthening treatment of the solder contact surface on the nozzle 26 further reduces the adhesion force between the solder and the nozzle, facilitating separation.

[0040] Step 7, Pressure Welding and Cooling: The robotic arm 41 descends to reduce the gap between the first base material 61 and the second base material 62 to a preset welding distance, e.g., 0.2 mm, and a preset welding pressure, e.g., 0.5 MPa, is applied. This pressure is maintained for a certain time (e.g., 2 minutes) to allow the brazing filler metal to fully melt, flow, and react with the base material at the interface. After the welding heat treatment is completed, the controller 1 adjusts the heating power of the second heater 43 and the third heater 44, gradually reducing them according to a preset program to achieve precise control of the cooling rate of the weldment. For example, the temperature can be set to decrease every 1-2 minutes to keep the cooling rate below 10°C / min. The temperature is then slowly cooled to below 100°C at a rate not exceeding 10°C / min (e.g., 5°C / min or 8°C / min) to complete the connection between the SiC ceramic and the Cu metal. The slower cooling rate helps to fully release thermal stress and prevent cracking of the ceramic base material.

[0041] It should be noted that the device of this invention is particularly suitable for continuous production on an assembly line. After the first set of base materials is welded and removed according to the above steps, the second set of base materials to be welded can be immediately moved into the workstation, and steps one through seven can be repeated. During continuous production, the atmosphere protection component 5 can maintain continuous operation, continuously providing a protective atmosphere to prevent oxidation of active elements caused by equipment start-up or workpiece turnover; the solder supply component 3 can continuously supply liquid solder to ensure the continuity of coating; the controller 1 coordinates and controls each component to operate automatically according to a preset program, realizing continuous and efficient production of multiple sets of workpieces, and significantly improving production efficiency and product quality consistency. During continuous production, the controller 1 monitors the working status of each component in real time, including the solder liquid level and temperature in the storage tank 33, the flow rate and temperature of the protective gas, the heating temperature of the base material, and the gap between the nozzle 26 and the base material. When the parameters are detected to exceed the set range, the controller 1 automatically adjusts, such as replenishing solder, adjusting the heating power, or fine-tuning the position of the robotic arm, to ensure that the coating and welding conditions of each set of workpieces are consistent, thereby ensuring the stability and consistency of product quality.

[0042] It should be noted that the above-mentioned process parameters (such as gap, temperature, pressure, ultrasonic parameters, cooling rate, etc.) can all be optimized and selected according to the actual base material combination, solder type, and joint performance requirements. For example, for solders with good fluidity, the amplitude can be appropriately reduced or the ultrasonic treatment time can be shortened; for base materials that are difficult to wet, the amplitude can be appropriately increased or the treatment time can be extended. Those skilled in the art, inspired by the technical solution of this invention, can make reasonable parameter adjustments without creative effort to achieve reliable bonding between ceramics and metals.

[0043] Figure 5 The images show actual photographs of SiC ceramics and Cu metal joined using the method of this invention. As can be seen from the images, the ceramics are well-formed and free of macroscopic defects such as cracks, which preliminarily verifies the feasibility of this invention.

[0044] The above description is merely a preferred embodiment of the present invention and is not intended to limit the scope of protection of the present invention. For those skilled in the art, various modifications, substitutions, or improvements can be made to the technical solutions of the present invention without departing from the spirit and principles of the invention, and these modifications, substitutions, or improvements should also be considered within the scope of protection of the present invention.

Claims

1. An integrated apparatus for material brazing and welding under a protected atmosphere, characterized in that, include: Atmosphere protection component (5) for providing a protective atmosphere; Solder supply assembly (3) for storing and conveying liquid solder; The ultrasonic coating assembly (2) includes an ultrasonic tool head (23) and a nozzle (26) connected to the ultrasonic tool head (23). The nozzle (26) is connected to the solder supply assembly (3) and is used to receive liquid solder and allow the liquid solder to overflow. Welding assembly (4) for clamping and moving a first base material (61) and a second base material (62) that are arranged opposite to each other; Controller (1) is used to control the above components; The nozzle (26) is disposed between the first base material (61) and the second base material (62), and maintains a gap with both of them; The ultrasonic coating assembly (2) is used to apply ultrasonic vibration to liquid solder that overflows and adheres to the surface of the nozzle (26) and is in contact with the two base materials under the protective atmosphere, so that the liquid solder simultaneously forms a brazing coating on the opposing surfaces of the first base material (61) and the second base material (62). The welding assembly (4) is used to move the base material after coating is completed so that the nozzle (26) moves out between the first base material (61) and the second base material (62) and welds the two materials with brazing coating.

2. The integrated brazing and welding apparatus for materials under protected atmosphere as described in claim 1, characterized in that, The solder supply assembly (3) further includes a first heater (37) disposed in a storage tank (33); the welding assembly (4) includes a top mechanical claw (42) for clamping and heating the first base material (61) and a bottom mechanical claw (45) for carrying and heating the second base material (62), the top mechanical claw (42) is provided with a second heater (43), and the bottom mechanical claw (45) is provided with a third heater (44).

3. The integrated brazing and welding apparatus for materials under protected atmosphere as described in claim 1, characterized in that, The ultrasonic coating assembly (2) also includes an ultrasonic transducer (21) and an amplitude transformer (22). The ultrasonic transducer (21) is connected to the ultrasonic tool head (23) through the amplitude transformer (22). The amplitude transformer (22) is provided with a cooling water inlet (25) and a cooling water outlet (24) for cooling and protecting the ultrasonic transducer (21).

4. The integrated brazing and welding apparatus for materials under atmospheric protection according to claim 1, characterized in that, The solder supply assembly (3) includes a first gas source (31), a storage tank (33), and a conveying channel (35); the first gas source (31) is connected to the storage tank (33) through a pipeline equipped with a flow controller (32) for introducing gas into the storage tank (33) to generate air pressure; the storage tank (33) is connected to the nozzle (26) through the conveying channel (35) and, driven by the air pressure, conveys liquid solder to the nozzle (26) through the conveying channel (35); the storage tank (33) is equipped with a pressure relief valve (34).

5. The integrated brazing and welding apparatus for materials under atmospheric protection according to claim 4, characterized in that, The ultrasonic tool head (23) is coaxially connected to the nozzle (26). The nozzle (26) has a hollow structure and its surface opposite to the first base material (61) and the second base material (62) is provided with a plurality of nozzle holes (261) communicating with its interior.

6. The integrated brazing and welding apparatus for materials under atmospheric protection according to claim 5, characterized in that, The diameter of the nozzle (261) is 0.2-1 mm; the inner wall of the material conveying channel (35) and the inner and outer surfaces of the nozzle (26) are all treated with corrosion-resistant reinforcement.

7. The integrated brazing and welding apparatus for materials under atmospheric protection according to claim 1, characterized in that, The atmosphere protection component (5) includes a second gas source (51), a gas pipe (53), and a fourth heater (54) disposed on the gas pipe (53). One end of the gas pipe (53) is connected to the second gas source (51), and the other end is directed toward the nozzle (26) and the area where the base material is located.

8. A method for integrating material brazing and welding using the apparatus described in any one of claims 1-7, characterized in that, Includes the following steps: S1: Place the nozzle (26) between the first base material (61) and the second base material (62) that are set opposite to each other, and maintain a gap of 0.5 to 1 mm between them; S2: Under a protective atmosphere, liquid solder is delivered to the nozzle (26) so that the liquid solder overflows and adheres to the surface of the nozzle (26) while contacting the two base materials; ultrasonic vibration is applied to the liquid solder adhering to the surface of the nozzle (26) so that the liquid solder simultaneously forms a brazing coating on the opposing surfaces of the first base material (61) and the second base material (62); S3: Move the nozzle (26) out of the area between the first base material (61) and the second base material (62); S4: Pressure welding is performed on the first base material (61) and the second base material (62) with the brazing coating to complete the connection.

9. The method according to claim 8, characterized in that, In S2, the amplitude of the ultrasonic vibration is 2-10 μm, the frequency is 15-100 kHz, and the application time is 1-10 seconds.

10. The method according to claim 8, characterized in that, In S4, after welding is completed, the weldment is cooled to below 100°C at a cooling rate not exceeding 10°C / min.

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