Cored Brazing Wire Forming Without Lamination
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Solution Overview
Problem
Conventional brazing methods require a lamination step for producing a band with controlled thickness and width, increasing production costs and resulting in non-isotropic spreading of the metal alloy, affecting the quality of the joint.
Innovation Solution
A method involving a solid metal or metal alloy wire with a circular cross-section is stamped into a U-shape across its entire diameter, filled with brazing flux, and calibrated to achieve a constant thickness, eliminating the need for lamination and ensuring isotropic displacement during melting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a lamination step is used to produce a band with controlled thickness and width, then the desired diameter with controlled overlapping can be obtained, but the production cost significantly increases
Solution Approach 1:
The invention extracts and eliminates the lamination step from the conventional brazing wire manufacturing process. By directly forming the U-shaped band from a single metal strip without requiring lamination, the process removes the costly and complex lamination operation while still achieving the desired controlled thickness and width for the final brazing wire
Solution Approach 2:
The invention segments the manufacturing process into distinct stages: forming the U-shaped band from a single strip, depositing flux in the U-shaped space, and then welding the arms together. This segmentation allows each step to be optimized independently, eliminating the need for lamination while maintaining precision
2Manufacturing precision
If a lamination step is used to produce a band with controlled thickness and width, then the desired diameter with controlled overlapping can be obtained, but the device complexity increases
Solution Approach 1:
The invention extracts and eliminates the lamination step from the conventional brazing wire manufacturing process. By directly forming the U-shaped band from a single metal strip without requiring lamination, the process removes the costly and complex lamination operation while still achieving the desired controlled thickness and width for the final brazing wire
Solution Approach 2:
The invention performs preliminary forming of the U-shaped band from a single metal strip before flux deposition and welding. This preliminary action establishes the controlled geometry early in the process, eliminating the need for subsequent lamination operations and simplifying the overall device complexity
3Ease of manufacture
If the wall thickness of the metal or metal alloy wire is not constant, then the production process is simpler, but the spreading by capillarity becomes non-isotropic affecting the quality of the joint
Solution Approach 1:
The invention ensures uniform wall thickness throughout the brazing wire by controlling the forming process of the U-shaped band and the subsequent welding of its arms. This local quality control at critical stages (forming and welding) ensures isotropic capillary spreading and reliable joint quality without requiring overly complex processes
Solution Approach 2:
The invention implements process control mechanisms that monitor and adjust the forming and welding parameters to maintain constant wall thickness. This feedback control ensures that the brazing wire achieves uniform dimensions, resulting in isotropic spreading behavior and high-quality joints
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 produces a cored brazing wire with a longer usable length and better-controlled flux content, achieving a more consistent and efficient brazing process with reduced production costs and improved joint quality.
Implementation Method 1
the metal or the metal alloy melts, and spreads by capillarity at the level of the surfaces to be assembled to form a joint
Data Source
AI summary
A method for producing a brazing wire consists of unwinding a solid metal or metal alloy wire, of circular or substantially circular cross-section and subjecting the wire to a stamping operation between rotating rollers, the periphery of which respectively having a die for receiving the full wire and a punch capable of deforming the wire and of generating a U-shaped cross-section across substantially the entire original diameter of the wire. The method also consists of filling the volume defined by the U using brazing flux or pickling flux in a powder or paste form and closing the arms of the U, after filling of the volume with the flux, one on top of the other with the end of one of the arms of the U overlapping the other. The method also consists of calibrating and shaping the resulting wire, according to the desired diameter and cross-section.