Fluid Flow Channel Fabrication via Groove Sealing and Diffusion Welding

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Solution Overview

Problem

Existing methods for creating structures with internal cooling channels, such as diffusion welding, face limitations when channels have complex geometries or small sections, as they can lead to deformation or leaks, and require the use of intermediate materials that complicate dimensioning and mechanical performance.

Innovation Solution

The method involves machining grooves in a base plate, sealing them with strips using laser welding, and then applying a lid through hot isostatic compression diffusion welding, eliminating the need for tubes and preventing channel deformation, while allowing for varied channel cross-sections and geometries.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If diffusion welding is used to assemble structures with internal cooling channels, then complex geometries can be achieved, but channel deformation and leaks occur due to gas pressure penetration

Engineering Contradiction:

Improvechannel geometry complexityVSAvoidchannel dimensional accuracy

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The grooves are sealed with strips before the diffusion welding process begins. This preliminary sealing action prevents gas pressure from penetrating into the channels during welding, thereby avoiding channel deformation while enabling the use of complex geometries

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The sealing is achieved by dividing the channel system into sealed segments using strips that block the groove openings. This segmentation allows the welding process to proceed without gas pressure intrusion while maintaining the integrity of complex channel geometries

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If tubes are used to create cooling channels between plates, then simple channel geometries can be achieved, but complex channel sections and bends cannot be produced

Engineering Contradiction:

Improvechannel geometry varietyVSAvoidmanufacturing complexity

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The invention extracts the sealing function from the tube assembly process and implements it separately by sealing grooves with strips before welding. This allows the use of simple plate structures instead of complex tube assemblies while achieving the same sealing effect

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

By sealing the grooves preliminarily before welding, the invention enables the creation of complex channel geometries directly in the plates without requiring pre-assembled tube structures, thereby simplifying the manufacturing process

Inventive Principle:

Principle #10Preliminary action

3Reliability

If inlets and outlets of channels are sealed to prevent gas penetration, then welding can proceed, but channels are crushed by pressure

Engineering Contradiction:

Improvewelding qualityVSAvoidchannel dimensional accuracy

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The grooves are sealed with strips before the diffusion welding and pressurization process. This preliminary sealing allows the application of high pressure during welding without causing channel crushing, as the pressure is contained by the strips rather than acting directly on the channels

Inventive Principle:

Principle #10Preliminary action

4Manufacturing precision

If pressure is reduced to prevent channel crushing, then channel geometry is preserved, but resistance of plate/plate junction decreases

Engineering Contradiction:

Improvechannel dimensional accuracyVSAvoidjoint resistance

Core Design Contradiction:

Manufacturing precisionVSStrength

Solution Approach 1:

By sealing the grooves with strips before applying pressure, the invention decouples the pressure application from channel vulnerability. This allows high pressure to be applied during diffusion welding to ensure strong joint resistance, while the strips prevent channel crushing simultaneously

Inventive Principle:

Principle #10Preliminary action

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 enables the creation of complex, high-temperature-resistant structures with precise channel geometries and seals, avoiding deformation and leaks, and enhancing mechanical strength by isolating welds from the outside medium.

Implementation Method 1

sealing them with strips by laser welding

Methodology Applied

Scientific EffectLaser welding: Laser Beam Welding

Implementation Method 2

assembling by diffusion welding is performed

Methodology Applied

Scientific EffectDiffusion welding: Diffusion Welding

Implementation Method 3

submitted to a HIC cycle, the parameters of which (time, temperature, pressure) depend on the nature of the metal material(s)

Methodology Applied

Scientific EffectHot isostatic compression: Hot Isostatic Pressing

Data Source

PatentUS7850061B2Method for making a component including fluid flow channels

Publication Date: 2010.12.14 COMMISSARIAT A LENERGIE ATOMIQUE ET AUX ENERGIES ALTERNATIVES

AI summary

A method for making a component including fluid flow channels formed by making a plurality of grooves (12), in at least one face (21) of a base plate (10); having opposite ends so that the grooves have open top sides; scalably blocking the open top side of each groove and diffusion-welding a lid by hot isostatic compression onto the face (21) of the base plate (10) to cover each of the strips leaving open the fluid flow channels at one or both opposite ends of the base plate for allowing pressurized gas to penetrate into the flow channels.