Simultaneous Inner Outer Heating Brazing Large Aeronautical Parts
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Solution Overview
Problem
Existing brazing techniques for large-sized metal parts, particularly in aeronautics, face challenges such as high thermal cycle costs due to inertia, difficulties in controlling gas pressure and temperature parameters, and significant temperature gradients that extend the brazing time and increase costs.
Innovation Solution
A method and device for simultaneous inner and outer surface heating of metal parts using inner and outer heating means, with controlled heating and cooling by inert gases like argon or nitrogen, reducing temperature gradients and brazing cycle time, and utilizing a brazing device adapted for large-sized revolution parts with dimensions suitable for parts up to 3 meters in diameter and 9 tons in mass.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If single-sided heating is used for large-sized parts, then the heating process is simpler, but significant temperature gradients extend the brazing time and increase costs
Solution Approach 1:
The heating system is segmented into multiple independent heating zones (first heating device for outer surface, second heating device for inner surface) that can operate simultaneously. This segmentation allows parallel heating of different regions, reducing temperature gradients and overall heating time while maintaining manageable complexity through modular design.
Solution Approach 2:
The heating approach transitions from single-sided (one-dimensional) heating to multi-sided (three-dimensional) heating by adding internal heating capability. This dimensional change enables heat to be applied from multiple directions simultaneously, dramatically reducing temperature gradients and brazing cycle time for large-sized parts.
2Strength
If metal brazing tooling is used, then structural support is provided, but additional thermal cycle costs occur due to thermal inertia
Solution Approach 1:
Instead of using heavy metal tooling throughout, the invention applies localized ceramic coatings only where thermal insulation is needed. This local quality approach provides thermal insulation to reduce thermal cycle costs while maintaining structural support from the underlying metal tooling, optimizing the balance between strength and energy efficiency.
Solution Approach 2:
The tooling system combines metal structural components with ceramic insulating coatings to create a composite structure. The metal provides mechanical strength and support, while the ceramic layer reduces thermal inertia and thermal cycle costs, achieving both structural support and energy efficiency.
3Strength
If gas pressure brazing is used, then assembly is achieved, but control of pressure, time and temperature parameters is difficult to avoid crushing and optimize marking
Solution Approach 1:
Ceramic coatings are introduced as an intermediary material between the metal tooling and the workpiece. This intermediary layer acts as a protective barrier that prevents direct metal-to-metal contact, reducing the risk of crushing and marking while allowing for more forgiving parameter control during the brazing process.
Solution Approach 2:
The use of ceramic coatings creates a chemically inert environment between the tooling and workpiece, preventing unwanted chemical reactions and physical adhesion that could lead to marking or crushing. This inert barrier simplifies parameter control by decoupling the mechanical and thermal functions.
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 reduces the brazing cycle time, eliminates the need for a thermal bell, and lowers manufacturing costs by achieving more homogeneous temperature distribution and faster heating, while maintaining high brazing temperatures up to 1200 degrees Celsius.
Implementation Method 1
a heating step of the outer surface of the outer part by an outer heating means and... a heating step of the inner surface of the inner part by an inner heating means
Implementation Method 2
heating step of the outer surface of the outer part by an outer heating means
Implementation Method 3
a cooling step by a gas of at least one heating means; the cooling step is carried out by means of an inert gas; the cooling step is carried out by means of argon and/or nitrogen
Data Source
AI summary
The present disclosure relates to a method for producing a final metal part for a nacelle of a turbojet. The method includes brazing at least two parts, one being an inner part having an inner surface and the other being an outer part having an outer surface. The method further includes a step of heating the outer surface of the outer part using an external heating means, and a step of heating the inner surface of the inner part using an internal heating means.