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 the brazing sheet, and a method for forming an article of manufacture 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 includes a first aluminum alloy, the first aluminum alloy including, in 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, and optionally incidental elements, impurities, and aluminum. The first aluminum alloy satisfies formula (I): 3.1 ≦([Mg]+[Fe]+[Cr]) / [Si], where [Mg], [Fe], [Cr], and [Si] are the weight percent concentrations of manganese, iron, chromium, and silicon in the first aluminum alloy, respectively.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Provisional Patent Application No. 63 / 480,625, filed January 19, 2023, the contents of which are incorporated herein by reference.

[0002] The present disclosure relates to brazing sheets, articles formed from or including brazing sheets, and methods of forming articles. [Background technology]

[0003] Various devices, such as heat exchangers, can be formed from stacked, specially designed metal plates, such as brazing sheets. Plate-type heat exchangers function by circulating two fluids (e.g., liquids, refrigerants, or a combination thereof) on either side of the plates, allowing heat exchange between the fluids. Designing acceptable brazing sheets and sourcing the feedstock to manufacture them present challenges. Summary of the Invention

[0004] One non-limiting embodiment of the present disclosure is directed to a brazing sheet including a brazing layer and a core layer. The brazing layer includes a 4XXX series aluminum alloy. The core layer includes a first aluminum alloy containing, in weight percent based on the total weight of the first aluminum alloy, 0.2-0.6 silicon, 1.5-2 manganese, 0.01-0.2 titanium, 0.5-2.5 copper, 0-0.5 iron, 0-0.5 magnesium, 0-0.5 zinc, 0-0.3 chromium, 0-0.25 zirconium, and optionally additional elements, impurities, and aluminum. The first aluminum alloy satisfies the formula: 3.1≦([Mg]+[Fe]+[Cr]) / [Si], where [Mg], [Fe], [Cr], and [Si] are the weight percent concentrations of manganese, iron, chromium, and silicon in the first aluminum alloy, respectively.

[0005] An additional non-limiting embodiment of the present disclosure relates to an article including or formed from a component including a structural element comprising, in whole or in part, a brazing sheet. The brazing sheet includes a brazing layer and a core layer. The brazing layer includes a 4XXX series aluminum alloy. The core layer includes a first aluminum alloy, the first aluminum alloy including, in weight percent based on the total weight of the first aluminum alloy, 0.2-0.6 silicon, 1.5-2 manganese, 0.01-0.2 titanium, 0.5-2.5 copper, 0-0.5 iron, 0-0.5 magnesium, 0-0.5 zinc, 0-0.3 chromium, 0-0.25 zirconium, and optionally additional elements, impurities, and aluminum. The first aluminum alloy satisfies the formula: 3.1 ≦([Mg]+[Fe]+[Cr]) / [Si], where [Mg], [Fe], [Cr], and [Si] are the weight percent concentrations of manganese, iron, chromium, and silicon in the first aluminum alloy, respectively.

[0006] A still further non-limiting embodiment according to the present disclosure is directed to a method for forming an article of manufacture. The method includes contacting a first part including a first material with a second part including all or a portion of a brazing sheet including a brazing layer and a core layer. The brazing layer includes a 4XXX series aluminum alloy. The core layer includes a first aluminum alloy including, in weight percent based on the total weight of the first aluminum alloy, 0.2-0.6 silicon, 1.5-2 manganese, 0.01-0.2 titanium, 0.5-2.5 copper, 0-0.5 iron, 0-0.5 magnesium, 0-0.5 zinc, 0-0.3 chromium, 0-0.25 zirconium, and optionally additional elements, impurities, and aluminum. The first aluminum alloy satisfies the formula: 3.1 ≦([Mg]+[Fe]+[Cr]) / [Si], where [Mg], [Fe], [Cr], and [Si] are the weight percent concentrations of manganese, iron, chromium, and silicon in the first aluminum alloy, respectively. The method includes brazing the first part to the second part by a process including at least one of controlled atmosphere brazing and vacuum brazing.

[0007] It should be understood that the invention disclosed and described herein is not limited to the aspects summarized in this Summary. The reader will understand these and other details in light of the following detailed description of various non-limiting and non-exhaustive aspects hereof. [Brief explanation of the drawings]

[0008] The configuration and advantages of the embodiments, as well as the method for achieving them, will become more apparent and the embodiments will be better understood by referring to the following description in conjunction with the accompanying drawings.

[0009] [Figure 1] 1 is a schematic side view of a first non-limiting embodiment of a brazing sheet according to the present disclosure.

[0010] [Figure 2]FIG. 2 is a schematic side view of a second non-limiting embodiment of a brazing sheet according to the present disclosure.

[0011] [Figure 3] FIG. 10 is a schematic side view of a third non-limiting embodiment of a brazing sheet according to the present disclosure.

[0012] [Figure 4] FIG. 10 is a schematic side view of a fourth non-limiting embodiment of a brazing sheet according to the present disclosure.

[0013] [Figure 5] FIG. 10 is a schematic side view of a fifth non-limiting embodiment of a brazing sheet according to the present disclosure.

[0014] [Figure 6] 1 is a flowchart illustrating a non-limiting embodiment of a method for forming an article according to the present disclosure.

[0015] The examples set forth herein illustrate particular embodiments in one or more forms, and such examples should not be construed in any way as limiting the scope of the appended claims. DETAILED DESCRIPTION OF THE INVENTION

[0016] Various embodiments are described and illustrated in this disclosure to provide a comprehensive understanding of the structure, function, and use of the disclosed articles and methods. The various embodiments described and illustrated in this disclosure are non-limiting and non-exhaustive. Therefore, the present invention is not limited by the description of the various non-limiting and non-exhaustive embodiments disclosed in this disclosure. Rather, the present invention is defined only by the claims. The features and features illustrated and / or described in connection with various embodiments may be combined with the features and features of other embodiments. Such modifications and variations are intended to be included within the scope of this specification. Accordingly, the claims may be amended to recite any features or features explicitly or inherently described or otherwise explicitly or inherently supported herein. Further, applicants reserve the right to amend the claims to affirmatively disclaim any features or features that may exist in the prior art. The various embodiments disclosed and described herein may comprise, consist of, or consist essentially of the features and features variously described herein.

[0017] References herein to "various embodiments," "some embodiments," "one embodiment," "one embodiment," "non-limiting embodiments," or similar phrases mean that a particular configuration, structure, step, or feature described in connection with an example is included in at least one embodiment. Thus, appearances of the phrases "various embodiments," "some embodiments," "one embodiment," "embodiments," "non-limiting embodiments," or similar phrases herein do not necessarily refer to the same embodiment. Furthermore, particular described configurations, structures, steps, or features may be combined in any suitable manner in one or more embodiments. Thus, a particular configuration, structure, step, or feature illustrated or described in connection with one embodiment may be combined, in whole or in part, without limitation, with the configurations, structures, steps, or features of one or more other embodiments. Such variations and modifications are intended to be included within the scope of the present embodiments.

[0018] Various non-limiting embodiments of the alloys described in connection with the present disclosure optionally include the intentional addition of incidental elements that, for example, can aid in the production of the alloy and / or improve one or more properties or characteristics of the alloy. For example, certain non-limiting embodiments of alloys according to the present disclosure may be configured to include the intentional incidental addition of one or more grain refiners and one or more deoxidizers. In various non-limiting embodiments, the total concentration of incidental elements in an alloy according to the present disclosure preferably does not exceed 1 weight percent based on the total weight of the alloy, and the concentration of any single incidental element preferably does not exceed 0.2 weight percent based on the total weight of the alloy.

[0019] Various non-limiting embodiments of the alloys described in connection with the present disclosure may be configured to contain impurities. As used herein, an "impurity" is an element or other substance that may be present in an alloy according to the present disclosure in relatively trace concentrations, but that is not intentionally added to improve the manufacturability of the alloy or to affect the properties or characteristics of the alloy. For example, impurities in alloys according to the present disclosure may be present in trace concentrations due to, for example, the unavoidable or unintentional presence of impurities in feed materials, local atmospheric contamination during melting, refining, or other processing, or contamination from contact with processing equipment. In various non-limiting embodiments, the total concentration of impurities in the alloys described in the present disclosure preferably does not exceed 0.15 weight percent based on the total weight of the alloy, and the concentration of any single impurity preferably does not exceed 0.05 weight percent based on the total weight of the alloy.

[0020] Brazing sheets typically contain alloying elements, but it would be advantageous if the alloying elements could be separated from scrap brazing sheets or from used or scrapped manufactured articles formed from or containing brazing sheets. Typically, brazing sheets contain multiple layers, each with its own unique compositional specifications. Separating the layers of a brazing sheet, removing individual alloying elements from a brazing sheet, or separating layers from an article containing or formed from a brazing sheet can be difficult. As a result, the brazing sheet or article may have to be recycled as a whole without isolating the layer or region in which the desired elements are present. Certain alloying elements in scrap brazing sheets or scrap articles may be present in concentrations that are undesirable for use as recycled feedstock in the manufacture of specific aluminum alloy sheets incorporated into brazing sheets. For example, some alloying elements may be present in the brazing sheet or scrap article in concentrations that adversely affect the properties of the core layer of the brazing sheet, such as corrosion resistance, grain size, and / or other microstructural characteristics of the core layer.

[0021] The inventors have discovered that a balance of chemical modification from elements present in scrap material and intentional addition of additional elements can provide the desired properties to an aluminum alloy sheet used in a brazing sheet. The present disclosure provides a brazing sheet that exhibits acceptable or excellent formability, corrosion resistance, brazing ability, strength, and diffusion resistance, as well as recyclability. An embodiment of a brazing sheet according to the present disclosure may include a brazing layer and a core layer. The brazing layer includes a 4XXX series aluminum alloy. The core layer includes a first aluminum alloy, which contains, in weight percent based on the total weight of the first aluminum alloy, 0.2-0.6 silicon, 1.5-2 manganese, 0.01-0.2 titanium, 0.5-2.5 copper, 0-0.5 iron, 0-0.5 magnesium, 0-0.5 zinc, 0-0.3 chromium, 0-0.25 zirconium, and optionally incidental elements, impurities, and aluminum. The first aluminum alloy satisfies the formula: 3.1 ≦([Mg]+[Fe]+[Cr]) / [Si], where [Mg], [Fe], [Cr], and [Si] are the weight percent concentrations of manganese, iron, chromium, and silicon in the first aluminum alloy, respectively.

[0022] As used herein, the term "core layer" refers to the substrate layer of a brazing sheet. In various non-limiting embodiments, the "core layer" may be substantially located in the center of the brazing sheet. However, the location of the core layer within a 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 on both sides by other layers of the brazing sheet. For example, the core layer may be partially or completely exposed on one side of the brazing sheet. Also, in various non-limiting embodiments, the core layer of an embodiment of a brazing sheet according to the present disclosure may be completely covered on both sides by other layers of the brazing sheet, may be at least partially exposed on at least one side, or may be completely exposed on at least one side.

[0023] Referring to FIG. 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 bonded together (e.g., roll-pressed) to form the brazing sheet 100. The brazing sheet 100 shown in FIG. 1 includes two layers. However, the brazing sheet 100 may also be configured to include one or more additional layers, such as, for example, three layers as shown in FIGS. 2 and 5, four layers as shown in FIG. 4, or five layers as shown in FIG. 3, as described herein.

[0024] Referring again to FIG. 1 , the brazing sheet 100 can be brazed as part of a production process to form a manufactured article. For example, in one brazing process, 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, causing the brazing layer 104 to melt and flow, wet the surface of the component, and then solidify to form a suitable brazed joint between the brazing sheet 100 and the component. In various embodiments, the temperature to which the assembly is heated during the brazing process can be high enough to melt the soluble phase of the brazing sheet 100. Typically, 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.

[0025] During brazing, it may be desirable for the core layer 102 not to melt so that the core layer 102 retains the desired strength, structural integrity, and corrosion performance. For example, in some embodiments, the core layer 102 may be configured to have a core layer solidus temperature that is higher than the brazing temperature to which the brazing sheet 100 is subjected. For example, the core layer 102 may be configured to have a core layer solidus temperature of at least 600°C, such as at least 605°C, at least 610°C, or at least 615°C.

[0026] In various embodiments, the core layer 102 is non-homogenized and may be H-tempered. As used herein, H-temper has the meaning defined in ANSI H35.1 / H35.1(M)-2017. The core layer 102 may form a brown band that is resistant to corrosion. The brown band may form in the core layer 102 when silicon diffuses from the brazing layer 104 into the core layer 102 and precipitates with manganese and iron in solid solution during the brazing process. The brown band in the core layer 102 may comprise small AlxMnySiz or Alx(Mn,Fe,Cr)ySiz dispersoids that form a band near the interface between the brazing layer 104 and the core layer 102. The formation of dispersoids at the interface pulls manganese from solid solution, creating a more electrochemically negative region in the brazing sheet 100 that is anodic with respect to the center of the brazing sheet 100, thereby increasing the overall corrosion resistance of the core layer 102. Because the presence of silicon in the core layer 102 can affect brown band formation and the solidus temperature of the core, highly corrosion-resistant core layers containing high levels of silicon typically do not rely on brown band formation for corrosion resistance. The inventors have discovered that by adjusting the chemical composition of the core layer 102 to compensate for the high levels of silicon that can result from using brazing sheet scrap in the manufacture of the brazing sheet 100, silicon and other alloying elements can be present in the core layer 102 while still achieving the desired brown band formation for improved corrosion resistance.

[0027] The core layer 102 of the brazing sheet 100 includes a first aluminum alloy, such as a 3XXX series aluminum alloy. The first aluminum alloy may include, by weight percent based on the total weight of the first aluminum alloy, 0.2-0.6 silicon, e.g., 0.2-0.55 silicon, 0.25-0.55 silicon, 0.25-0.5 silicon, 0.3-0.55 silicon, 0.3-0.5 silicon, 0.3-0.45 silicon, or 0.3-0.4 silicon. The silicon content may be derived from scrap material used in the manufacture of the core layer 102.

[0028] It has been discovered that maintaining an appropriate balance of certain elements within the core layer 102 allows the core layer 102 to exhibit desirable properties while still containing a significant amount of scrap material. For example, the first aluminum alloy may satisfy the formula: X ≦ ([Mg] + [Fe] + [Cr]) / [Si], where [Mg], [Fe], [Cr], and [Si] are the weight percent concentrations of manganese, iron, chromium, and silicon in the first aluminum alloy, respectively. X may be at least 3.1, e.g., 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 exceed 10. For example, X may be in the range of 3.1 to 10.

[0029] In various non-limiting embodiments, maintaining an appropriately high manganese-to-silicon weight ratio in the core layer 102 allows the core layer 102 to exhibit desirable properties while including a significant amount of scrap material. For example, the manganese-to-silicon weight ratio in the first aluminum alloy can be at least 3.1, e.g., 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 manganese-to-silicon weight ratio can be 10 or less. For example, the manganese-to-silicon weight ratio in the first aluminum alloy can be in the range of 3.1 to 10.

[0030] The first aluminum alloy may include, in weight percent based on the total weight of the first aluminum alloy, 1.5 to 2 manganese, e.g., 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.

[0031] The first aluminum alloy may contain, in weight percent 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.

[0032] The first aluminum alloy of the core layer 102 contains, in 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, and optionally incidental elements, impurities, and aluminum. In various non-limiting embodiments, the first aluminum alloy contains, in 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, and optionally incidental elements, impurities, and aluminum. In certain non-limiting embodiments, the first aluminum alloy contains, in 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, and optionally incidental elements, impurities, and aluminum.

[0033] The chemistry of the core layer 102 may be modified to include other corrosion protection mechanisms in addition to or as an alternative to the browning. For example, the core layer 102 may be modified to include a concentration of copper that provides galvanic protection to the core layer 102. Too high a copper concentration may undesirably affect the properties of the core layer 102. In various examples, the core layer 102 may be configured such that the weight ratio of copper to manganese in the first aluminum alloy is 1 or less, e.g., 0.9 or less, or 0.8 or less.

[0034] The core layer 102 may be formed from an ingot containing, for example, at least 10% scrap material, e.g., 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 may be feed material, such as primary aluminum (e.g., grade P1020) and optional hardeners. The amount of scrap material may be adjusted based on the amount of silicon or other alloying elements contained in the scrap material. For example, the amounts of scrap material and feed material contained in the melt used to form the ingot for the core layer 102 may be selected so that the silicon content of the resulting core layer 102 is 0.6 wt.% or less, based on the total weight of the core layer 102. The scrap material may be, for example, pre-consumer waste generated during the manufacturing of brazing sheet or its components (e.g., revert) and / or post-consumer waste obtained from a third-party source. Scrap material may include, for example, scrap brazing sheet, used or discarded articles formed from or including brazing sheet, and / or scrap material from other sources.

[0035] The brazing layer 104 of the brazing sheet 100 includes a second aluminum alloy, such as a 4XXX series aluminum alloy. In various non-limiting embodiments, the second aluminum alloy contains, in weight percent based on the total weight of the aluminum alloy, 5-15 silicon, 0-2 magnesium, 0-1 iron, 0-3 zinc, 0-2 copper, 0-1 manganese, 0-0.3 bismuth, and optionally incidental elements, impurities, and aluminum. The brazing layer 104 exhibits a brazing layer solidus temperature that is less than the solidus temperature of the core layer, e.g., at least 5°C less, at least 10°C less, at least 15°C less, at least 20°C less, at least 25°C less, or at least 30°C less than the solidus temperature of the core layer. By ensuring that the solidus temperature of the brazing layer is sufficiently lower than the solidus temperature of the core layer, the brazing process allows for heating the brazing sheet 100 to a suitable temperature, which can melt the brazing layer 104 while the core layer 102 remains substantially solid.

[0036] The thickness of each layer within the brazing sheet 100 can be configured based on the desired structural characteristics of the article (e.g., a heat exchanger) being produced from or incorporating the brazing sheet 100. For example, in various non-limiting embodiments, the core layer 102 is approximately 1 / 2 inch thick relative to the total thickness of the brazing sheet 100 (i.e., t total In various non-limiting embodiments, the brazing layer 104 may have a first thickness t1 that may be in the range of 60% to 97% of the total thickness (t total ) in a range of 3% to 20% of the total thickness (t ). In various non-limiting embodiments, the first thickness t 1 is greater than the second thickness t 2. In certain non-limiting embodiments, the brazing sheet 100 may have a second thickness t 1 that is greater than the total thickness (t total ) is in the range of 100 μm to 5 mm, for example, in the range of 200 μm to 1 mm.

[0037] In various non-limiting embodiments, a brazing sheet according to the present disclosure may be configured with one or more layers in addition to the core layer and brazing layer. For example, referring to the non-limiting embodiment shown schematically in FIG. 2 , brazing sheet 200 includes core layer 102, brazing layer 104, and layer 206 disposed on a second surface 102b of core layer 102 opposite first surface 102a of core layer 102 on which brazing layer 104 is deposited. In various embodiments, layer 206 may be a second brazing layer configured similarly to brazing layer 104 described above, or layer 206 may be a waterside liner. In various non-limiting embodiments, core layer 102, brazing layer 104, and layer 206 are bonded (roll-pressed) together to form brazing sheet 200.

[0038] In embodiments where layer 206 is the second brazing layer, layer 106 and brazing layer 104 may have the same composition or different compositions.

[0039] In embodiments in which layer 206 is a waterside liner, the waterside liner provides corrosion protection to brazing sheet 200 and may come into contact with coolant during use of an article comprising all or a portion of brazing sheet 200. The waterside liner may comprise a third aluminum alloy comprising, in weight percent based on the total weight of the 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, and optionally incidental elements, impurities, and aluminum.

[0040] In various non-limiting embodiments, a brazing sheet according to the present disclosure may be configured with one or more interliner layers. Referring to the non-limiting embodiment shown schematically in FIG. 3 , brazing sheet 300 includes core layer 102, brazing layer 104, layer 206, interliner layer 308, and interliner layer 310. Interliner layer 308 is interposed between brazing layer 104 and core layer 102, and interliner layer 310 is interposed between layer 206 and core layer 102. In various non-limiting embodiments, core layer 102, brazing layer 104, layer 206, interliner layer 308, and interliner layer 310 are bonded together (e.g., roll-pressed) to form brazing sheet 300.

[0041] Interliner layers 308 and 310 of brazing sheet 100 each include a third aluminum alloy containing, in weight percent based on the total weight of the third aluminum alloy, 0.05-1.5 silicon, 0-2 manganese, 0-2 magnesium, 0-2 copper, 0-0.8 iron, 0-3 zinc, 0-0.5 zirconium, 0-1.0 chromium, 0-0.5 bismuth, 0-0.3 titanium, and optionally incidental elements, impurities, and aluminum. The compositions of interliner layers 308 and 310 may be the same or different.

[0042] In various non-limiting embodiments, the brazing sheet of the present disclosure may not include the interliner layer 310, and layer 206 may be in direct contact with the core layer 102. For example, referring to the non-limiting embodiment shown schematically in FIG. 4 , brazing sheet 400 includes core layer 102, brazing layer 104, layer 206, and interliner layer 308. In various non-limiting embodiments, core layer 102, brazing layer 104, layer 206, and interliner layer 308 are bonded together (e.g., roll-pressed) to form brazing sheet 400.

[0043] In various non-limiting embodiments, a brazing sheet according to the present disclosure may be configured without interliner layer 310 or layer 206, and core layer 102 may be exposed on one side. Referring to the non-limiting embodiment shown schematically in Figure 5, brazing sheet 500 includes core layer 102, brazing layer 104, and interliner layer 308. In various non-limiting embodiments, core layer 102, brazing layer 104, and interliner layer 308 are bonded together (e.g., roll-pressed) to form brazing sheet 500.

[0044] The thickness of each layer within brazing sheet 200, brazing sheet 300, brazing sheet 400, and brazing sheet 500 can be configured based on the desired structural characteristics of the article (e.g., a heat exchanger) produced from or incorporating brazing sheet 100. For example, in various non-limiting embodiments, core layer 102 is approximately 1 / 2 inch thick, approximately 1 / 4 inch thick, and approximately 1 / 4 inch thick. total ), which may be in the range of 60% to 93% of the total thickness (t ). In various non-limiting embodiments, interliner layers 308 and 310, if present, may be configured with third thicknesses t3 and t3', the sum of the two thicknesses being less than the total thickness (t total In various non-limiting embodiments, brazing layer 104 and layer 206 may be configured with second thicknesses t2 and t2', the sum of the two thicknesses being less than the total thickness (t) of each brazing sheet 200, 300, 400, or 500. total ) in the range of 3% to 20%. In various non-limiting embodiments, the first thickness t1 is greater than each of the second thicknesses t2 and t2' and greater than each of the third thicknesses t3 and t3'. In certain non-limiting embodiments, the total thickness (t total) is in the range of 100 μm to 5 mm, for example in the range of 200 μm to 1 mm.

[0045] The brazing sheet 200 may be suitable for at least one of controlled atmosphere brazing and vacuum brazing. For example, the brazing sheet 200 may be configured with layers having a composition that makes the brazing sheet 200 suitable for controlled atmosphere brazing and / or vacuum brazing. In various non-limiting embodiments in which the brazing sheets 100, 200, 300, 400, and 500 may be subjected to a brazing process utilizing a flux, diffusion of magnesium from a brazing sheet according to the present disclosure may be undesirable because it may interfere with the flux. In various non-limiting embodiments, the brazing sheets according to the present disclosure are configured to inhibit diffusion from the brazing sheet (e.g., inhibit magnesium diffusion) so that the 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 may have a composition suitable for vacuum brazing (e.g., fluxless vacuum brazing). In various non-limiting embodiments in which the brazing sheets 100, 200, 300, 400, and 500 are subjected to flux-free brazing (e.g., brazing in an inert atmosphere with residual O in a CAB furnace without the use of any flux), magnesium diffusion from the brazing sheet can be advantageous, for example, to dissolve an oxide layer formed on the brazing layer 104 and / or promote wettability of the brazed surface.

[0046] In various non-limiting embodiments, an article, such as a heat exchanger, may be configured with a structural element comprising all or a portion of brazing sheet 100, 200, 300, 400, and / or 500. The heat exchanger has a galvanic corrosion resistance evaluated according to ASTM G85 Annex A3 (2019) of at least 20 days, e.g., at least 25 days, or at least 30 days. The heat exchanger may 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 may be configured with a tubular shape.

[0047] FIG. 6 provides a block diagram of one non-limiting embodiment of a method according to the present disclosure for forming an article of manufacture, such as a heat exchanger. The method embodiment includes contacting a first portion including a first material with a second portion including all or a portion of a non-limiting embodiment of a brazing sheet according to the present disclosure. For example, a non-limiting embodiment of a method according to the present disclosure may include contacting a first portion including a first material with a second portion including all or a portion of brazing sheet 100, 200, 300, 400, 500, and / or other embodiments of a brazing sheet according to the present disclosure (FIG. 4, step 602). In various non-limiting embodiments, the first portion can be brazed to the second portion by a process including at least one of controlled atmosphere brazing and vacuum brazing (FIG. 6, step 604). In various non-limiting embodiments, the first material includes aluminum or an aluminum alloy.

[0048] The following numbered sections are directed to various non-limiting embodiments and aspects according to the present disclosure.

[0049] Section 1. A brazing sheet, a brazing layer comprising a 4XXX series aluminum alloy; a core layer comprising a first aluminum alloy, the core layer comprising, in weight percent based on the total weight of the first aluminum alloy: 0.2 to 0.6% silicon, 1.5 to 2 manganese and Titanium of 0.01 to 0.2 and 0.5 to 2.5 copper and 0 to 0.5 iron and 0 to 0.5 magnesium and 0-0.5 zinc and 0 to 0.3 chromium and 0 to 0.25 zirconium, Optionally, an accessory element; Impurities and a core layer comprising aluminum; A brazing sheet having the formula: 3.1 ≦ ([Mg] + [Fe] + [Cr]) / [Si], where [Mg], [Fe], [Cr], and [Si] are the weight percent concentrations of manganese, iron, chromium, and silicon in the first aluminum alloy, respectively.

[0050] Section 2. 2. The brazing sheet of claim 1, wherein the formula is 3.2 ≦([Mg] + [Fe] + [Cr]) / [Si], where [Mg], [Fe], [Cr], and [Si] are the weight percent concentrations of manganese, iron, chromium, and silicon in the first aluminum alloy, respectively.

[0051] Section 3. the first aluminum alloy comprising, in weight percent based on the total weight of the first aluminum alloy: 0.2 to 0.5 silicon, 1.6-2 manganese and 0.1 to 0.2 titanium and 0.5 to 1 copper, 0.1 to 0.4 iron, 0 to 0.1 magnesium and 0 to 0.25 zinc and 0 to 0.3 chromium and 0 to 0.25 zirconium, Optionally, an accessory element; Impurities and 3. The brazing sheet according to any one of items 1 and 2, further comprising aluminum.

[0052] Section 4. the first aluminum alloy comprising, in weight percent based on the total weight of the first aluminum alloy: 0.3 to 0.4 silicon, 1.6-2 manganese and 0.1 to 0.2 titanium and 0.5 to 1 copper, 0.1 to 0.4 iron, 0 to 0.1 magnesium and 0 to 0.25 zinc and 0 to 0.3 chromium and 0 to 0.25 zirconium, Optionally, an accessory element; Impurities and 4. The brazing sheet according to any one of items 1 to 3, further comprising aluminum.

[0053] Section 5. 5. The brazing sheet according to any one of items 1 to 4, wherein the weight ratio of copper to manganese in the first aluminum alloy is 1 or less.

[0054] Section 6. 6. The brazing sheet according to any one of items 1 to 5, wherein the core layer is subjected to a non-homogenizing treatment.

[0055] Section 7. the 4XXX series aluminum alloy in the brazing layer, in weight percent based on the total weight of the 4XXX series aluminum alloy, 5 to 15 silicon, 0-2 magnesium and Iron from 0 to 1, 0-3 zinc and 0-2 copper and 0-1 manganese and 0 to 0.3 bismuth and Optionally, an accessory element; Impurities and 7. The brazing sheet according to any one of items 1 to 6, further comprising aluminum.

[0056] Section 8. 8. The brazing sheet according to any one of items 1 to 7, wherein the core layer and the brazing layer are bonded together.

[0057] Section 9. Item 9. The brazing sheet according to any one of items 1 to 8, further comprising a waterside liner layer, the core layer being interposed between the waterside liner layer and the brazing layer.

[0058] Section 10. Item 10. The brazing sheet according to item 9, wherein the core layer, the waterside liner layer, and the brazing layer are bonded together.

[0059] Section 11. the waterside liner layer comprises a third aluminum alloy, the third aluminum alloy being, in weight percent based on a total weight of the third aluminum alloy: 0.5 to 12 zinc and 0.1 to 1.2 silicon, Iron from 0 to 1, 0-0.3 copper and 0 to 1.5 manganese and 0-0.6 magnesium and Titanium 0-0.2 and 0 to 0.2 zirconium, Optionally, an accessory element; Impurities and Item 11. The brazing sheet according to any one of items 9 to 10, further comprising aluminum.

[0060] Section 12. the brazing layer is a first brazing layer disposed on the first surface of the core layer; Item 9. The brazing sheet according to any one of items 1 to 8, further comprising a second brazing layer disposed on a second surface of the core layer opposite the first surface of the core layer, the second brazing layer comprising a 4XXX series aluminum alloy.

[0061] Section 13. Item 13. The brazing sheet according to item 12, wherein the core layer, the first brazing layer, and the second brazing layer are bonded together.

[0062] Section 14. Item 13. The brazing sheet according to item 12, further comprising a first interliner layer, the first interliner layer being interposed between the core layer and the first brazing layer.

[0063] Section 15. Item 15. The brazing sheet according to item 14, further comprising a second interliner layer, the second interliner layer being interposed between the core layer and the second brazing layer.

[0064] Section 16. Item 12. The brazing sheet according to any one of items 1 to 11, further comprising an interliner layer, the interliner layer being interposed between the core layer and the brazing layer.

[0065] Section 17. Item 17. The brazing sheet according to any one of items 1 to 16, wherein the brazing sheet has a composition suitable for at least one of controlled atmosphere brazing and vacuum brazing.

[0066] Section 18. the core layer has a first thickness in the range of 60% to 97% of the total thickness of the brazing sheet; Item 2. The brazing sheet according to item 1, wherein the brazing layer has a second thickness in the range of 3% to 20% of the total thickness of the brazing sheet.

[0067] Section 19. Item 19. The brazing sheet according to any one of items 1 to 18, wherein the brazing sheet comprises at least 30% scrap material.

[0068] Section 20. 20. A manufactured article comprising a structural element comprising all or part of the brazing sheet according to any one of items 1 to 19, or formed from a part comprising a structural element.

[0069] Section 21. Item 21. The article according to item 20, wherein the article is a tubular-shaped article.

[0070] Section 22. 2. An article of any one of headings 20 or 21, including a heat exchanger.

[0071] Section 23. 23. The article of claim 22, wherein the article has a galvanic corrosion resistance of at least 20 days as evaluated according to ASTM G85 Annex A3 (2019).

[0072] Section 24. 1. A method for forming an article of manufacture, comprising: A first part including a first material is contacted with a second part including all or part of the brazing sheet according to any one of items 1 to 19; and brazing the first portion to the second portion by a process comprising at least one of controlled atmosphere brazing and vacuum brazing.

[0073] Section 25. 25. The method of paragraph 24, wherein the first material comprises aluminum or an aluminum alloy.

[0074] Section 26. 24. The method of claim 23, wherein the article of manufacture is a heat exchanger.

[0075] Section 27. Item 19: The brazing sheet according to any one of items 1 to 19, wherein the first aluminum alloy is, in weight percent based on the total weight of the first aluminum alloy, 0.2 to 0.5 silicon, 1.6-2 manganese and Titanium of 0.01 to 0.2 and 0.5 to 1 copper, 0.1 to 0.4 iron, 0 to 0.1 magnesium and 0 to 0.25 zinc and 0 to 0.3 chromium and 0 to 0.25 zirconium, Optionally, an accessory element; Impurities and A brazing sheet comprising aluminum.

[0076] Section 28. Item 19: The brazing sheet according to any one of items 1 to 19, wherein the first aluminum alloy is, in weight percent based on the total weight of the first aluminum alloy, 0.3 to 0.4 silicon, 1.6-2 manganese and Titanium of 0.01 to 0.2 and 0.5 to 1 copper, 0.1 to 0.4 iron, 0 to 0.1 magnesium and 0 to 0.25 zinc and 0 to 0.3 chromium and 0 to 0.25 zirconium, Optionally, an accessory element; Impurities and A brazing sheet comprising aluminum.

[0077] Section 29. A brazing sheet, a brazing layer comprising a 4XXX series aluminum alloy; a core layer comprising a first aluminum alloy, the first aluminum alloy being, in weight percent based on a total weight of the first aluminum alloy: 0.2 to 0.6 silicon, manganese from 1.5 to 2, wherein the weight ratio of manganese to silicon in the first aluminum alloy is at least 3.1; 0.1 to 0.2 titanium and 0.5 to 2.5 copper and 0 to 0.5 iron and 0 to 0.5 magnesium and 0-0.5 zinc and 0 to 0.3 chromium and 0 to 0.25 zirconium, Optionally, an accessory element; Impurities and A brazing sheet comprising: aluminum; and a core layer comprising:

[0078] Section 30. A brazing sheet, a brazing layer comprising a 4XXX series aluminum alloy; a core layer comprising a first aluminum alloy, the first aluminum alloy being, in weight percent based on a total weight of the first aluminum alloy: 0.2 to 0.6 silicon, manganese from 1.5 to 2, wherein the weight ratio of manganese to silicon in the first aluminum alloy is at least 3.1; Titanium of 0.01 to 0.2 and 0.5 to 2.5 copper and 0 to 0.5 iron and 0 to 0.5 magnesium and 0-0.5 zinc and 0 to 0.3 chromium and 0 to 0.25 zirconium, Optionally, an accessory element; Impurities and A brazing sheet comprising: aluminum; and a core layer comprising:

[0079] Unless otherwise indicated herein, all numerical parameters should be understood in all instances to be modified by the term "about" which is preceded by the term "about" and that such numerical parameters should take into account the inherent variation characteristics of the underlying measurement technique used to determine the numerical value of such parameters. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter set forth herein should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

[0080] Additionally, any numerical ranges recited in this disclosure include all subranges subsumed within the recited range. For example, a range of "1 to 10" includes all subranges between (and including) the recited minimum of 1 and the recited maximum of 10, i.e., having a minimum of 1 or more and a maximum of 10 or less. Additionally, all ranges recited herein include the endpoints of the recited range. For example, a range of "1 to 10" includes the endpoints 1 and 10. Any maximum numerical limitation recited herein is intended to include all lower numerical limitations subsumed therein, and any minimum numerical limitation recited herein is intended to include all higher numerical limitations subsumed therein. Accordingly, applicants reserve the right to amend this specification, including the claims, to explicitly recite subranges subsumed within the explicitly recited ranges. All such ranges are inherently set forth herein.

[0081] As used herein, the grammatical articles "a," "an," and "the" are intended to include "at least one" or "one or more," unless otherwise indicated, even if "at least one" or "one or more" is expressly used in a particular instance. Accordingly, the foregoing grammatical articles are used herein to refer to one or more (i.e., "at least one") of the particular identified elements. Furthermore, the use of a singular noun includes the plural, and the use of a plural noun includes the singular, unless the context of use requires otherwise.

[0082] Those skilled in the art will recognize that the articles and methods described herein, and the accompanying discussion, are used as examples for conceptual clarity, and that various structural modifications are contemplated. Consequently, as used herein, the specific examples / embodiments described and the accompanying discussion are intended to represent their more general classes. In general, the use of any specific example is intended to represent its class, and the absence of specific components, devices, operations / acts, and objects should not be construed as limiting. While this disclosure provides descriptions of various specific embodiments for the purpose of illustrating various aspects of the disclosure and / or its potential applications, those skilled in the art will recognize that variations and modifications occur. Accordingly, the invention(s) described herein should be understood to be at least as broad as they are claimed, and not more narrowly defined by the specific illustrative embodiments provided herein.

Claims

1. A brazing sheet, a brazing layer comprising a 4xxx series aluminum alloy; a core layer comprising a first aluminum alloy, the first aluminum alloy being, in weight percent based on a 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, an accompanying element; Impurities and a core layer comprising aluminum; A brazing sheet, wherein the formula is 3.1 ≦([Mg] + [Fe] + [Cr]) / [Si], and [Mg], [Fe], [Cr], and [Si] are the weight percent concentrations of manganese, iron, chromium, and silicon in the first aluminum alloy, respectively.

2. 2. The brazing sheet of claim 1, wherein the formula is 3.2≦([Mg]+[Fe]+[Cr]) / [Si], and [Mg], [Fe], [Cr], and [Si] are weight percent concentrations of manganese, iron, chromium, and silicon in the first aluminum alloy, respectively.

3. 2. The brazing sheet of claim 1, wherein the first aluminum alloy comprises, in weight percent based on the total weight of the first aluminum alloy: 0.2 to 0.5 silicon; Manganese 1.6-2 and 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, an accompanying element; Impurities and A brazing sheet comprising aluminum.

4. 2. The brazing sheet of claim 1, wherein the first aluminum alloy comprises, in weight percent based on the total weight of the first aluminum alloy: 0.3 to 0.4 silicon; Manganese 1.6-2 and 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, an accessory element; Impurities and A brazing sheet comprising aluminum.

5. 2. The brazing sheet according to claim 1, wherein the weight ratio of copper to manganese in the first aluminum alloy is 1 or less.

6. The brazing sheet according to claim 1 , wherein the core layer is subjected to a non-homogenization treatment.

7. 2. The brazing sheet of claim 1, wherein the 4xxx series aluminum alloy of the brazing layer comprises, in weight percent based on the total weight of the 4xxx series aluminum alloy: 5 to 15 silicon atoms, 0-2 magnesium, Iron from 0 to 1, 0 to 3 zinc, 0-2 copper and 0 to 1 manganese and 0 to 0.3 bismuth, Optionally, an accessory element; Impurities and A brazing sheet comprising aluminum.

8. The brazing sheet of claim 1 , wherein the core layer and the brazing layer are bonded together.

9. The brazing sheet according to claim 1 , further comprising a waterside liner layer, the core layer being interposed between the waterside liner layer and the brazing layer.

10. The brazing sheet of claim 9 wherein the core layer, the waterside liner layer, and the brazing layer are bonded together.

11. 10. The brazing sheet of claim 9, wherein the waterside liner layer comprises a third aluminum alloy, the third aluminum alloy comprising, in weight percent based on a total weight of the third aluminum alloy: 0.5 to 12 zinc, 0.1 to 1.2 silicon; Iron from 0 to 1, 0 to 0.3 copper, 0 to 1.5 manganese, 0 to 0.6 magnesium, Titanium of 0 to 0.2 and 0 to 0.2 zirconium; Optionally, an accessory element; Impurities and A brazing sheet comprising aluminum.

12. the brazing layer is a first brazing layer disposed on a first surface of the core layer, 10. The brazing sheet of claim 1, further comprising a second brazing layer disposed on a second surface of the core layer opposite the first surface of the core layer, the second brazing layer comprising a 4xxx series aluminum alloy.

13. The brazing sheet of claim 12 , wherein the core layer, the first brazing layer, and the second brazing layer are bonded together.

14. 13. The brazing sheet of claim 12, further comprising a first interliner layer, said first interliner layer being interposed between said core layer and said first brazing layer.

15. 15. The brazing sheet of claim 14, further comprising a second interliner layer, said second interliner layer being interposed between said core layer and said second brazing layer.

16. The brazing sheet according to claim 1 , further comprising an interliner layer, said interliner layer being interposed between said core layer and said brazing layer.

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

18. The brazing sheet according to claim 1, A brazing sheet, 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. 10. The brazing sheet of claim 1, wherein the brazing sheet contains at least 30% scrap material.

20. 10. An article of manufacture comprising or formed from a part including a structural element comprising all or part of the brazing sheet of claim 1.

21. 21. The article of claim 20, wherein the article is a tubular-shaped article.

22. 21. The article of claim 20, wherein the article comprises a heat exchanger.

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

24. 1. A method for forming an article of manufacture, comprising: contacting a first portion including a first material with a second portion including all or part of the brazing sheet of claim 1; and brazing the first portion to the second portion by a process comprising at least one of controlled atmosphere brazing and vacuum brazing.

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

26. 25. The method of claim 24, wherein the article of manufacture is a heat exchanger.

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