Concave Brazing Seam Geometry for Slag and Gas Discharge
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Solution Overview
Problem
The existing brazing technologies face challenges with inadequate slag discharge and gas overflow effects, leading to poor quality of brazing joints.
Innovation Solution
A brazing joint with a concave-shaped seam and unequal gap distances, combined with strip-shaped textures on the base metals and the application of ultrasonic vibration and magnetic fields, promotes solder rheology and gas overflow by facilitating the discharge of bubbles and slags.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional brazing joints with uniform gap are used, then the brazing process is simple, but the slag discharge and gas overflow effects are poor
Solution Approach 1:
The patent applies asymmetry by designing the gap between base metals to be non-uniform, with a first gap distance at the edge and a second gap distance at the center, where the first distance is greater than the second distance. This asymmetric gap configuration creates a curved surface that facilitates slag and gas discharge paths, resolving the contradiction between manufacturing simplicity and harmful factor removal.
Solution Approach 2:
The patent introduces a new dimension by adding strip-shaped textures on the welding surfaces of base metals. These textures extend from the first distance location to the second distance location and provide additional pathways for solder flow, slag discharge, and gas overflow, transforming a two-dimensional gap problem into a three-dimensional solution that maintains manufacturing simplicity while improving discharge effects.
2Object-generated harmful factors
If a concave-shaped brazing seam with unequal gap distances is used, then slag discharge and gas overflow are improved, but the manufacturing complexity increases
Solution Approach 1:
The patent applies local quality by creating different gap distances at different locations: a larger first gap distance at the edge for slag/gas discharge and a smaller second gap distance at the center for strong metallurgical bonding. This localized variation in gap configuration optimizes both discharge efficiency and joint strength without requiring complex overall structure changes.
Solution Approach 2:
The patent implements preliminary action by pre-forming the asymmetric gap structure and strip-shaped textures on the base metal welding surfaces before the brazing process. This pre-preparation ensures that when solder is applied and heated, the discharge pathways are already in place, allowing slag and gas to escape efficiently during brazing without requiring complex real-time control mechanisms.
3Ease of manufacture
If uniform gap configuration is used, then manufacturing is easier, but solder rheology and capillary fluidity are insufficient
Solution Approach 1:
The patent applies curvature by creating a curved surface through the asymmetric gap configuration, where the gap transitions from a larger first distance at the edge to a smaller second distance at the center. This curved geometry naturally guides solder flow from the edge toward the center, improving capillary fluidity and rheology control without requiring complex manufacturing processes.
Solution Approach 2:
The patent adds dimensional complexity by introducing strip-shaped textures on the welding surfaces that extend across the gap. These textures create micro-channels that enhance solder wetting and flow control, transforming a simple uniform gap into a multi-dimensional flow control system that maintains manufacturing ease while achieving precise solder rheology control.
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 approach significantly improves the efficiency of slag discharge and welding quality by ensuring bubbles and slags are effectively removed, enhancing the overall brazing process efficiency and product quality.
Implementation Method 1
the gap defines a first distance and a second distance, the first distance is located at an edge of the gap, the second distance is located at the edge or inside of the gap, the first distance is greater than the second distance, and a curved surface is formed between the location of the first distance and the location of the second distance for transition
Implementation Method 2
combined with strip-shaped textures on the base metals and the application of ultrasonic vibration and magnetic fields, promotes solder rheology and gas overflow by facilitating the discharge of bubbles and slags
Implementation Method 3
combined with strip-shaped textures on the base metals and the application of ultrasonic vibration and magnetic fields, promotes solder rheology and gas overflow
Data Source
AI summary
A brazing joint, a brazing method, and a device for promoting solder rheology and gas overflow are provided. The brazing joint includes a first base metal, a second base metal, and a brazing seam located therebetween. The brazing seam is formed by filling a solder in a gap formed by welding surfaces of the first and the second base metal and melting it to connect the first and the second base metal. The brazing seam is a concave-shaped brazing seam. The gap defines a first distance and a second distance, the first distance is located at an edge of the gap, the second distance is located at the edge or an inside of the gap, the first distance is greater than the second distance, and a curved surface is formed between the location of the first distance and the location of the second distance for transition.