Amorphous Ni-Based Brazing Foil for Uniform Corrosion-Resistant Joints
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Solution Overview
Problem
Existing nickel-based brazing foils face challenges in producing reliable, cost-effective joints with uniform geometry over long lengths due to issues with hard phase formation and geometrical variations, which affect the mechanical stability and corrosion resistance of soldered components.
Innovation Solution
A nickel-based brazing foil composition consisting of Ni, Cr, B, P, and optionally Si, Mo, Nb, Ta, W, Cu, Fe, and Co, with specific atomic percentage ranges, is produced using rapid solidification techniques to create an amorphous, ductile foil with a stable geometry and improved corrosion resistance, allowing for longer foil lengths with minimal thickness variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional nickel-based brazing foils are used, then the brazing process can be performed, but the foil exhibits hard phase formation and geometrical variations that reduce joint reliability and mechanical stability
Solution Approach 1:
The invention changes the chemical composition parameters of the brazing foil by introducing specific glass-forming elements (B, P, Si) in controlled amounts within defined ranges. This compositional parameter change prevents hard phase formation and ensures amorphous structure, thereby improving both joint reliability and geometric uniformity simultaneously
Solution Approach 2:
The invention creates a composite material system combining Ni base metal with glass-forming elements (B, P, Si) and Cr. This composite structure leverages the amorphous-forming capability of the glass elements to suppress crystalline hard phase formation, while the Ni matrix provides mechanical strength, achieving both reliability and precision improvements
2Reliability
If rapid solidification processes are used to produce amorphous foils, then the foil becomes ductile and reliable, but the production cost increases
Solution Approach 1:
The invention modifies the chemical composition parameters to include specific glass-forming elements in controlled amounts, which enable the material to form an amorphous structure through rapid solidification. This compositional tuning allows the foil to achieve ductility and reliability while controlling production costs by optimizing the balance between performance and material composition
3Temperature
If glass-forming elements are added to reduce melting temperature, then the processing temperature decreases, but the foil may lose mechanical stability
Solution Approach 1:
The invention optimizes the concentration parameters of glass-forming elements (B, P, Si) within specific ranges (0.1-5.0 at.%, 0.1-3.0 at.%, 0.1-2.0 at.% respectively) to achieve the desired balance. This parameter optimization ensures sufficient melting point reduction for easier processing while maintaining mechanical stability through controlled glass phase content that prevents excessive softening
Solution Approach 2:
The invention creates a composite structure where glass-forming elements form an amorphous matrix that lowers melting temperature, while the Ni base metal and Cr provide structural framework that maintains mechanical stability. The synergistic combination allows simultaneous achievement of low processing temperature and high mechanical strength
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 enables the production of continuous brazing foils with small geometric variations and enhanced corrosion resistance, reducing production costs and improving the reliability and mechanical stability of soldered joints, suitable for applications requiring high corrosion resistance and uniform solder distribution.
Implementation Method 1
produced by means of rapid solidification processes and are at least partially amorphous
Data Source
AI summary
A process for producing an amorphous ductile brazing foil is provided. According to one example embodiment, the method includes providing a molten mass, and rapidly solidifying the molten mass on a moving cooling surface with a cooling speed of more than approximately 105° C./sec to produce an amorphous ductile brazing foil. A process for joining two or more parts is also provided. The process includes inserting a brazing foil between two or more parts to be joined, wherein the parts to be joined have a higher melting temperature than that the brazing foil to form a solder joint and the brazing foil comprises an amorphous, ductile Ni-based brazing foil; heating the solder joint to a temperature above the liquidus temperature of the brazing foil to form a heated solder joint; and cooling the heated solder joint, thereby forming a brazed joint between the parts to be joined.