Composite Brazing Alloy Wire with Ductile Sheath
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Solution Overview
Problem
Brazing alloys with low ductility are difficult to form into wires due to their brittle nature, which leads to breakage during handling and application, especially when trying to achieve diameters less than 1 mm, as the wire drawing process is aggressive and tends to split, and existing methods either result in a rigid core or lack sufficient ductility for practical reduction.
Innovation Solution
A composite brazing alloy wire is formed with a ductile sheath and a core comprising discrete particles with a melting point at least 20% above the sheath's annealing temperature, having a size distribution where 25% by weight or less are particles less than 25 μm in size, and are spherical in form to prevent aggregation and ensure ductility, allowing for the production of wires with diameters less than 1 mm.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a low ductility alloy composition is used to achieve the desired brazing properties, then the brazing performance is improved, but the wire drawing process becomes difficult and the wire is prone to breakage
Solution Approach 1:
The alloy is segmented into two distinct phases: a ductile phase that provides workability during wire drawing and a low ductility phase that provides the desired brazing properties. This segmentation allows each phase to fulfill its specific function without compromising the other.
Solution Approach 2:
The invention creates a composite microstructure consisting of a ductile phase matrix with dispersed low ductility phase particles. This composite structure combines the advantages of both phases: the ductile phase enables wire drawing while the low ductility phase provides the required brazing characteristics.
2Manufacturing precision
If the wire diameter is reduced to less than 1 mm to achieve finer brazing applications, then the precision of the brazing joint is improved, but the wire becomes more prone to breakage during drawing
Solution Approach 1:
The alloy microstructure is segmented into a ductile phase matrix that provides toughness and resistance to breakage, with dispersed particles of the low ductility phase. This segmentation ensures that even at reduced diameters, the wire maintains sufficient strength to withstand the drawing process while achieving the required joint 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
The solution enables the successful drawing of brazing alloy wires with improved ductility, reducing the risk of breakage and allowing for practical reduction in diameter, facilitating the use of low ductility alloy compositions in brazing applications by maintaining the ductility of the sheath during the wire drawing process.
Implementation Method 1
the sheath has an annealing temperature in degrees K
Implementation Method 2
the particles have a melting point at least 20% above the annealing temperature of the sheath
Implementation Method 3
having a size distribution where 25% by weight or less are particles less than 25 μm in size, and are spherical in form to prevent aggregation and ensure ductility
Data Source
AI summary
Brazing alloy wire formed from a composite comprising a sheath of at least one ductile first phase and a core comprising particles of a different composition to the sheath, in which: the sheath has an annealing temperature in degrees K the particles have a melting point at least 20% above the annealing temperature of the sheath the particles have a size distribution in which 25% by weight or less comprise particles less than 25 μm in size the particles are discrete.