Aluminum Alloy Bonding via Controlled Liquid Phase Generation
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Solution Overview
Problem
Existing bonding methods for aluminum alloy materials face challenges such as deformation, limited configuration options, and high costs due to the need for melting, complex processes, and difficulty in achieving strong and reliable bonds, especially when bonding complex or hollow structures.
Innovation Solution
A novel bonding method utilizing a non-oxidizing atmosphere and controlled temperature to generate a specific range of liquid phases in aluminum alloy materials, with or without Mg, to achieve high reliability and minimal deformation, allowing for bonding of complex configurations without the need for melting or filler materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding method is used to bond aluminum alloy members, then bonding strength is improved, but deformation and local weakening occur due to melting
Solution Approach 1:
The invention utilizes controlled phase transition by generating a specific range of liquid phases (5-35% by mass) in the aluminum alloy material through temperature control, rather than complete melting. This partial phase transition enables bonding while minimizing deformation and maintaining manufacturing precision.
Solution Approach 2:
The invention changes the temperature parameter to control the generation of liquid phases within a specific range (5-35% by mass). By precisely controlling the temperature to achieve this specific phase ratio, the method resolves the contradiction between obtaining sufficient bonding strength and minimizing deformation.
2Productivity
If furnace-type brazing method is used to simultaneously bond multiple locations, then productivity is improved, but small passages may be filled with melted material
Solution Approach 1:
The invention utilizes controlled phase transition by generating a specific range of liquid phases (5-35% by mass) in the aluminum alloy material through temperature control, rather than complete melting. This partial phase transition enables bonding while minimizing deformation and maintaining manufacturing precision.
Solution Approach 2:
The invention applies partial action by generating only a specific range of liquid phases (5-35% by mass) rather than complete melting. This controlled partial phase transition provides sufficient bonding capability while preventing excessive material flow that would fill small passages.
3Manufacturing precision
If chemical bonding method using adhesive is used, then thermal deformation is reduced, but bonding strength and thermal conductivity are inferior
Solution Approach 1:
The invention utilizes controlled phase transition by generating a specific range of liquid phases (5-35% by mass) in the aluminum alloy material through temperature control, rather than complete melting. This partial phase transition enables bonding while minimizing deformation and maintaining manufacturing precision.
Solution Approach 2:
The invention changes the temperature parameter to control the generation of liquid phases within a specific range (5-35% by mass). By precisely controlling the temperature to achieve this specific phase ratio, the method resolves the contradiction between obtaining sufficient bonding strength and minimizing deformation.
4Strength
If physical bonding method using rivets is used, then bonding strength is achieved, but configuration is limited and tightness is compromised
Solution Approach 1:
The invention utilizes controlled phase transition by generating a specific range of liquid phases (5-35% by mass) in the aluminum alloy material through temperature control, rather than complete melting. This partial phase transition enables bonding while minimizing deformation and maintaining manufacturing precision.
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
This method enables superior bondability with minimal deformation, reduced material costs, and the ability to bond complex configurations simultaneously, while maintaining the original structure and thermal conductivity of the materials.
Implementation Method 1
a bonding process is carried out in a non-oxidizing atmosphere at a temperature, at which a ratio of a mass of liquid phases generated in the aluminum alloy material to the total mass of the aluminum alloy material falls within a range from 5% to 35%
Data Source
AI summary
A method of bonding two members including an aluminum alloy material as one member, and an aluminum alloy material or a pure aluminum material as the other member, the method being characterized in: that the aluminum alloy material for the one member and the aluminum alloy material for the other member are composed of an aluminum alloy containing Mg of not more than 0.5 mass %; and that a bonding process is carried out in a furnace having a non-oxidizing atmosphere at a temperature, at which a ratio of a mass of liquid phases generated in the aluminum alloy material defined as the one member to the total mass of the aluminum alloy material falls within a range from 5% to 35%, on the condition that there is either a coated fluoride-based flux or a coated chloride-based flux between both of the members to be bonded.