Clad Sheet Edge Segmentation for Recyclable Brazing Scrap
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The manufacturing of clad sheet products, particularly brazing sheets, faces challenges in controlling the composition of scrap material, especially when cladding layers contain high amounts of alloying elements or flux materials, leading to limited recyclability and increased material consumption.
Innovation Solution
A method involving a cladding plate with a centre section and edge sections made of different materials, attached as an integral unit to a core slab, allowing for controlled removal of edge sections during rolling to minimize scrap and optimize material usage, including hot rolling and cold rolling processes with optional annealing to achieve the desired gauge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cladding layers are made of alloys with high amounts of alloying elements (such as Si in braze claddings and Zn in sacrificial claddings), then the functionality and performance of the clad sheet product is improved, but the recyclability of scrap material becomes limited and more complicated
Solution Approach 1:
The cladding plate is segmented into a centre section and edge sections made of different materials. The centre section contains the high-alloying material (Al-Si brazing filler metal with 6-13% Si) for functional performance, while the edge sections are made of a different material that is easier to recycle. This segmentation allows the scrap to be separated into different compositional categories, improving recyclability while maintaining the functional benefits of the high-alloying centre section in the final product.
2Manufacturing precision
If edge portions are cut off during rolling to remove inadequate quality material, then the quality of the final product is improved, but the amount of scrap material increases
Solution Approach 1:
Different regions of the cladding plate are assigned different material qualities and functions. The centre section uses high-performance but difficult-to-recycle material where quality is critical, while the edge sections use material that is easier to recycle. This local differentiation allows the process to accept larger edge cut-offs (improving quality control) while minimizing the environmental and economic impact through easier scrap recyclability.
3Reliability
If flux-containing material is used in cladding layers to improve brazing performance, then the brazing quality is improved, but the scrap becomes more complicated to recycle
Solution Approach 1:
The flux-containing material is segregated to the centre section of the cladding plate, while the edge sections are made of material without or with minimal flux content. This segmentation concentrates the recycling complexity to a smaller portion of the total scrap, making the overall scrap management more feasible while maintaining the brazing quality benefits where the flux-containing material is applied.
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 precise control over the scrap composition and reduces material waste, particularly for complex composite materials, improving the recyclability and reducing the consumption of materials like flux-containing claddings.
Implementation Method 1
The clad sheets are produced by rolling to join the different layers and reduce the gauge to fit the intended use.
Implementation Method 2
The method further comprises rolling the assembly of a core layer and at least one cladding layer and reducing the thickness to a desired gauge
Implementation Method 3
The method further comprises rolling the assembly of a core layer and at least one cladding layer and reducing the thickness to a desired gauge
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention concerns a method for the manufacturing of a clad sheet product comprising a core layer(6)and at least one cladding layer, the method comprising rolling an assembly of a core layer and at least one cladding layer and reducing the thickness to a desired gauge, the core layer being made of an aluminium alloy, the at least one cladding layer comprising a centre section (2) and at least two edge sections (4, 5) positioned at opposite sides of the centre section (2) along the edges of the at least one cladding layer, the centre section being made of a material being an aluminium alloy or a composite material comprising a matrix of aluminium or an aluminium alloy, the edge sections along (4, 5) the edges being made of a material different from the material of the centre section, wherein the edge sections (4, 5) are cut off during or after the rolling. The invention further concerns a cladding plate useful in the method.