Ceramic CMC Brazing With Localized Heating and Reactive Filler
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Solution Overview
Problem
Joining ceramic or ceramic matrix composite components is challenging due to their high melting points and tendency to decompose before melting, making it difficult to form complex geometries from multiple parts.
Innovation Solution
A method involving positioning two ceramic or CMC parts adjacent to each other with a filler material and locally heating a metal or alloy on the filler's surface to form a molten braze, which infiltrates and reacts with the filler to join the parts, allowing for the use of localized heating and eliminating the need for melting point suppressants.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional joining methods are used for ceramic or CMC parts, then the parts can be joined together, but the parts must be heated to very high temperatures causing decomposition or requiring melting point suppressants
Solution Approach 1:
A filler material serves as an intermediary substance between the ceramic/CMC parts and the molten metal alloy. The filler material is disposed in the joint region and facilitates the reaction with the molten metal to form a strong bond, enabling joining at lower temperatures than traditional methods while maintaining reliability
Solution Approach 2:
The invention changes the temperature parameter by using localized heating to melt only the metal alloy portion rather than heating the entire assembly to the ceramic's melting point. This parameter change allows joining at lower temperatures, avoiding decomposition and eliminating the need for melting point suppressants
2Ease of manufacture
If multiple parts are used to form complex geometries, then manufacturing flexibility is improved, but joining difficulty increases due to high melting points and decomposition
Solution Approach 1:
The invention embraces segmentation by joining multiple ceramic/CMC parts together to form complex geometries. The localized brazing method enables this segmentation approach to work effectively by providing a reliable joining method that doesn't require melting the ceramic parts themselves, thus maintaining manufacturing flexibility while managing joining complexity
Solution Approach 2:
The filler material and molten metal alloy system acts as an intermediary joining mechanism that simplifies the overall joining process. Instead of directly melting and joining ceramic parts (which would be extremely complex), the intermediary metal-based system provides a manageable joining process that enables multi-part assembly
3Use of energy by moving object
If localized heating is used, then energy consumption is reduced and part temperatures are maintained lower, but the heating process becomes more complex
Solution Approach 1:
The invention applies local quality by concentrating heating only in the joint region where the metal alloy needs to be melted, rather than heating the entire ceramic assembly. This localized approach reduces overall energy consumption while the specialized heating device provides the necessary localized thermal input
4Ease of manufacture
If melting point suppressants are used, then joining is facilitated, but the high-temperature capabilities of the ceramic components are compromised
Solution Approach 1:
The filler material serves as an intermediary that enables joining without requiring melting point suppressants. By facilitating the reaction between the molten metal and ceramic surfaces, the filler material allows joining to proceed at lower temperatures, thereby preserving the high-temperature capabilities of the ceramic components
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
Enables the joining of ceramic or CMC components with complex geometries, maintaining lower part temperatures and improving high-temperature capabilities without the need for melting point suppressants, facilitating the creation of large or complex components from multiple parts.
Implementation Method 1
locally heating a metal or alloy disposed on a bulk surface of the filler material to form a molten metal or alloy
Implementation Method 2
infiltrating the filler material with the molten metal or alloy
Implementation Method 3
A constituent of the filler material reacts with a constituent of the molten metal or alloy to join the first part and the second part
Data Source
AI summary
The disclosure describes techniques for joining a first part including a ceramic or a CMC and a second part including a ceramic or a CMC using brazing. A technique may include positioning a filler material in a joint region between the first and second parts and a metal or alloy on a bulk surface of the filler material. The metal or alloy may be locally heated to melt the metal or alloy, which may infiltrate the filler material. A constituent of the molten metal or alloy may react with a constituent of the filler material to join the first and second parts. Another technique may include depositing a powder that includes the filler material and the metal or alloy in the joint region. Substantially simultaneously with depositing the powder, the powder may be locally heated. A constituent of the molten metal or alloy may react with a constituent of the filler material to join the first and second parts.