Gradient Braze Tape for Irregular Contours and Finish Machining

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Solution Overview

Problem

Conventional braze tapes and pre-sintered preforms struggle to provide near net-shape surfaces for irregularly shaped openings and contours in industrial components, and they are limited in their ability to withstand finish machining without exposing inappropriate layers.

Innovation Solution

A braze tape with distinct portions of low and high melting temperature alloy materials, including a central portion with a gradient mixture, ensuring adhesion and filling of irregular shapes while maintaining the high melting temperature alloy material for the component's surface during finish machining.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a homogenous braze tape with single or multiple layers of uniform material is used, then the material provides consistent adhesion properties, but the finish machining removes the harder exterior layer required for the surface and exposes the softer adhesion layer which is inappropriate for the component surface

Engineering Contradiction:

Improveadhesion strengthVSAvoidsurface quality

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The braze tape is divided into distinct layers: a first layer containing softer material for adhesion to the component, and a second layer containing harder material for the final surface. This segmentation allows each layer to perform its specific function - the first layer provides bonding while the second layer provides machinable surface quality.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the braze tape have different material properties tailored to their specific functions. The first layer has softer, more ductile properties optimized for adhesion to irregular contours, while the second layer has harder, more wear-resistant properties optimized for the final component surface.

Inventive Principle:

Principle #3Local quality

2Manufacturing precision

If a homogenous harder exterior layer is used for the braze tape surface, then the surface provides good machinability, but it reduces the ability to adhere to irregularly shaped openings and contours

Engineering Contradiction:

ImprovemachinabilityVSAvoidadhesion to irregular shapes

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The braze tape is segmented into functional layers where the first layer contains softer material that can conform to and adhere to irregular shapes and contours, while the second layer contains harder material that provides good machinability for the final surface.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The softer material is localized to the first layer that contacts irregular surfaces, providing adaptability, while the harder material is localized to the second layer that forms the final surface, providing machinability.

Inventive Principle:

Principle #3Local quality

3Stability of the object's composition

If pre-sintered preforms with bonded layers are used, then the structure provides rigidity, but it becomes more difficult to use with irregularly shaped openings and contours

Engineering Contradiction:

Improvestructural rigidityVSAvoidflexibility for irregular shapes

Core Design Contradiction:

Stability of the object's compositionVSEase of operation

Solution Approach 1:

The braze tape uses material composition changes between layers - the first layer has softer, more ductile material properties that allow flexibility and conformability to irregular shapes, while maintaining sufficient structural integrity for the application.

Inventive Principle:

Principle #35Parameter changes

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 braze tape effectively repairs complex openings and contours by ensuring adhesion and filling irregular shapes with a low melting temperature alloy, while the high melting temperature alloy material maintains the required properties for the component's surface, enhancing applicability and finish machining compatibility.

Implementation Method 1

the first portion includes a low melting temperature alloy material... ensuring adhesion and filling of irregular shapes

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

the first portion includes a low melting temperature alloy material, the second portion includes a high melting temperature alloy material... the central portion includes a mixture of the low melting temperature alloy material and the high melting temperature alloy material

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentUS12508675B1Braze tape with central region with low and high melting temperature alloy material, and related method

Publication Date: 2025.12.30 GE INFRASTRUCTURE TECH LLC

AI summary

A braze tape includes a first portion, a second portion, and a central portion located between and adjacent to the first portion and the second portion. The first portion includes a low melting temperature alloy material, the second portion includes a high melting temperature alloy material, and the central portion includes a mixture of the low melting temperature alloy material and the high melting temperature alloy material. The central portion may gradually change between the low melting temperature alloy material and the high melting temperature alloy material. A related method is also disclosed.