Additive-Manufactured Braze Joint for Temperature Sensor Strength
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Braze joints in temperature sensors, such as those in air data probes, suffer from strength issues due to inadequate braze liquation and wetting, which are influenced by factors like braze-gap sizing, part cleanliness, and operator technique, leading to potential alloy liquation and joint weaknesses.
Innovation Solution
A temperature sensor design featuring a baseplate and housing with a fusion zone or braze joint that fuses or brazes the bottom lip to the top surface, utilizing a fusion zone or braze joint that includes a lattice structure to enhance wetting and strength, and is manufactured using additive manufacturing techniques to ensure consistent joint formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional braze joint formation is used, then the process can be completed with conventional manufacturing methods, but the joint strength is insufficient due to inadequate braze liquation and wetting
Solution Approach 1:
The patent changes the manufacturing method from traditional braze joint formation to additive manufacturing, fundamentally altering the process parameters to achieve fusion zone formation with controlled depth (greater than 250 micrometers) and improved metallurgical bonding, eliminating the need for precise braze gap control
Solution Approach 2:
The patent replaces the mechanical braze joint formation process with additive manufacturing technology, substituting conventional metallurgical joining with a controlled deposition and fusion process that builds the joint layer by layer, ensuring consistent quality without operator skill dependency
2Reliability
If skilled operators are used to complete the braze joint, then the process can be performed with conventional techniques, but the process variability remains high and repeatability is poor
Solution Approach 1:
The additive manufacturing process is self-regulating with automated parameter control, where the system automatically maintains consistent fusion zone depth and metallurgical properties without requiring operator intervention or skill, eliminating process variability associated with manual braze joint formation
Solution Approach 2:
The patent extracts the critical process parameters from human operator control and embeds them directly into the additive manufacturing program, removing the source of variability and ensuring that the same parameters are consistently applied across all joints
3Manufacturing precision
If complex fixturing is used to ensure proper alignment, then the joint can be formed with correct positioning, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent merges the alignment and joining operations into a single additive manufacturing process step, where the housing is built directly onto the baseplate in the correct position, eliminating the need for separate fixturing and alignment procedures required in traditional braze joint formation
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a robust and repeatable braze joint with improved strength and consistency, reducing material costs and eliminating the need for complex fixturing and high operator skill, while maintaining structural integrity under harsh operating conditions.
Implementation Method 1
the bottom lip abuts and is fused to the top surface by a fusion zone
Implementation Method 2
The strut-to-baseplate joint is an important structural element for the temperature sensor. The strut-to-baseplate joints are formed as a braze joint.
Implementation Method 3
A temperature sensor design featuring a baseplate and housing with a fusion zone or braze joint that fuses or brazes the bottom lip to the top surface, utilizing a fusion zone or braze joint that includes a lattice structure to enhance wetting and strength, and is manufactured using additive manufacturing techniques
Implementation Method 4
utilizing a fusion zone or braze joint that includes a lattice structure to enhance wetting and strength
Data Source
AI summary
A temperature sensor may include a baseplate and a housing. The baseplate may include a rim portion with a top surface. The housing may include a strut portion with a bottom lip. The bottom lip may abut to and be one of fused to the top surface by a fusion zone or brazed to the top surface by a braze joint. The temperature sensor may include a fusion zone fusing the bottom lip and the top surface or a braze joint brazing the bottom lip and the top surface. A portion of or an entirety of the top surface of the rim portion may be utilized in the fusion zone or the braze joint. The bottom lip may include a lattice which improves the wetting of the braze joint.