Hollow Module Bead Diffusion Welding for Channel Precision
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing hollow zone modules through diffusion welding in hot isostatic compression face challenges such as channel deformation or crushing due to pressure, especially when channels have complex shapes or bends, leading to issues with dimensional precision and joint resistance.
Innovation Solution
A method involving the use of a bead of material placed along the recess contour of hollowed-out plates, which undergoes significant plastic deformation during hot isostatic compression, allowing for diffusion welding without deforming the plates, and subsequent high-pressure consolidation to achieve strong, leak-tight interfaces without channel deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If diffusion welding is performed without tubes under high pressure, then welding strength is improved, but channel geometry is degraded due to crushing
Solution Approach 1:
The patent applies preliminary action by performing diffusion welding at lower pressure before high-pressure consolidation. The beads are welded to the plates at lower pressure to establish strong joints, then the assembly is subjected to high pressure afterward to achieve leak-tight sealing without deforming the channel geometry during the critical welding phase
2Strength
If inlets and outlets are tightly sealed, then welding strength is improved, but channel geometry is degraded due to pressure crushing
Solution Approach 1:
The patent performs the welding action at lower pressure before applying high pressure for consolidation. The beads are welded to seal the inlets and outlets strongly at lower pressure, avoiding geometry degradation, then high pressure is applied to ensure leak-tight sealing of the entire assembly without deforming the channels
3Adaptability or versatility
If complex channel shapes with pronounced bends are used, then functionality is improved, but manufacturing complexity increases
Solution Approach 1:
The patent segments the manufacturing process into distinct phases: low-pressure diffusion welding to create strong joints, followed by high-pressure consolidation to achieve leak-tight sealing. This segmentation allows complex channel shapes to be manufactured without increasing overall process complexity, as each phase addresses specific requirements independently
Solution Approach 2:
The patent changes pressure parameters between manufacturing steps - using lower pressure during welding to avoid deformation, then increasing to high pressure for consolidation and sealing. This parameter change enables the production of complex channel geometries while maintaining manufacturing feasibility
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 production of hollow modules with complex shapes, such as 3D channels, that maintain their geometry and provide high thermal performance and chemical reactivity, while avoiding the need for brazing and ensuring the module's integrity and efficiency in applications like heat exchangers and reactors.
Implementation Method 1
processing the assembly to obtain welding by diffusion of each bead of material on the plates of the assembly that it contacts
Implementation Method 2
each bead of material undergoes significant plastic deformation favouring welding by diffusion
Implementation Method 3
consolidating the assembly by hot isostatic compression, carried out in such a way as to obtain diffusion welding of its elements
Implementation Method 4
obtain diffusion welding of its elements
Implementation Method 5
consolidation step being implemented by allowing the pressurizing gas to penetrate into said hollow zone
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention relates to a method for manufacturing a module (2) having a hollow area, including: a step of creating an assembly (4) including at least one recessed plate (6) having a recess (8) that is in communication with at least one surface (6a) while defining a recess outline (10a) thereon, and, between the surface (6a) and the plate (12) directly adjacent to the assembly, a cord (18) of material that extends along the outline of the recess; a step of treating the assembly, with a view to achieving a diffusion bonding of the cord (18) on the plate(s) (6, 12) in contact therewith so that the cord, along the associated recess outline (10a) thereof, forms a sealed bond of both plates (6, 12) between which the cord is arranged; and a step for consolidating the assembly by hot isostatic pressing.