Cold-Spray Braze Deposition for Consistent Nickel Powder Bonding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Manual braze material application in manufacturing is labor-intensive, prone to ergonomic injuries, and lacks consistency due to reliance on operator skill, especially in assemblies with numerous braze interfaces.
Innovation Solution
The implementation of a cold spray system that uses a combination of cold spray technology and braze-deposition material, controlled by a system with motion and flow controls, to achieve even deposition of nickel-enriched braze powder particles onto a substrate, allowing for precise application without melting the substrate, thereby enhancing adhesion and reducing labor efforts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual braze material application is used, then flexibility and adaptability are maintained, but labor intensity increases and consistency deteriorates
Solution Approach 1:
The automated dispensing system applies braze material without direct human intervention at the application point. The system self-regulates material flow through programmed parameters, eliminating the need for manual syringe dispensing while maintaining consistent application quality across all braze interfaces.
Solution Approach 2:
The patent replaces manual mechanical dispensing (syringe-type applicators operated by hand) with an automated mechanical dispensing system controlled by programmable parameters. This substitution eliminates ergonomic injuries associated with manual operation while maintaining the ability to adapt to different braze interface configurations through software control.
2Adaptability or versatility
If manual braze material application is used, then adaptability to different configurations is maintained, but consistency and precision deteriorate
Solution Approach 1:
The dispensing system incorporates dynamic control capabilities that allow parameters such as dispensing speed, material flow rate, and nozzle positioning to be adjusted in real-time based on the specific braze interface configuration. This enables consistent precision across varied applications while maintaining adaptability to different geometries and requirements.
Solution Approach 2:
The system employs feedback mechanisms including vision systems and sensors that monitor the braze interface configuration and automatically adjust dispensing parameters. This closed-loop control ensures consistent material application quality while adapting to variations in joint geometry, surface conditions, and assembly tolerances.
3Productivity
If automated dispensing is implemented, then productivity and consistency improve, but system complexity increases
Solution Approach 1:
The automated dispensing system is designed as a multi-functional platform that can handle various braze material types, nozzle configurations, and joint geometries through programmable control. This universal design consolidates multiple specialized tools into one system, improving productivity while managing complexity through standardized interfaces and modular components.
4Device complexity
If manual application is used, then equipment complexity is minimized, but ergonomic risks and labor costs increase
Solution Approach 1:
The automated dispensing system acts as an intermediary between the operator and the braze material application process. The operator programs and monitors the system from a safe distance, while the automated mechanism performs the physically demanding dispensing task. This intermediary system eliminates direct exposure to ergonomic risks such as repetitive strain and chemical exposure while maintaining equipment simplicity through modular design.
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 efficient, consistent, and ergonomic-friendly braze material deposition, reducing labor costs and improving the quality of braze interfaces by ensuring precise and even material distribution, while minimizing the risk of injuries.
Implementation Method 1
cold-spray braze material deposition
Implementation Method 2
rapid plastic deformation creates a bond to the substrate without melting
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
Aspects include supplying a plurality of nickel-enriched braze powder particles (122) to a cold spray system (101) through a particle supply inlet (120). The nickel-enriched braze powder particles are accelerated through a transfer tube (162) and out an exit (164) in the transfer tube towards a substrate to produce a braze cold-sprayed substrate. A component surface is positioned proximate to the braze cold-sprayed substrate. The braze cold-sprayed substrate is heated to bond the braze cold-sprayed substrate to the component surface.