Laser Brazing Metal Components via Indirect Thermal Conduction
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Solution Overview
Problem
Conventional brazing methods for finned-pack heat exchangers are unreliable, slow, unsafe, and limited in versatility, failing to ensure sealed joints with optimal mechanical and thermal fatigue strength, particularly for complex geometries and high-pressure applications.
Innovation Solution
A brazing method using laser radiation to heat metal components via an impact area outside the filler material, ensuring complete melting and capillary penetration without sublimation, combined with a robotic system for precise and automated application, allowing for any desired geometry and size of heat exchangers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual brazing with liquid-gas torch is used, then the operator can control the brazing process, but the method is slow, unsafe, and unreliable
Solution Approach 1:
The patent replaces the manual mechanical operation of liquid-gas torch brazing with an automated laser brazing system. The laser beam is precisely controlled by a robotic arm or CNC system to deliver consistent energy to the joint, eliminating human variability and improving both reliability and productivity simultaneously.
Solution Approach 2:
The patent changes the energy delivery parameters from conventional flame heating to concentrated laser radiation. By controlling laser power, speed, and focal position, the process achieves higher temperatures more quickly and consistently, improving brazing quality while increasing production speed.
2Productivity
If laser radiation is used to heat the filler material directly, then brazing speed increases, but the filler material sublimates instead of melting
Solution Approach 1:
The patent applies different heating strategies to different zones: the laser heats the base metal components to high temperature, while the filler material is supplied separately and melts from the heat conducted from the components. This localized thermal management prevents filler sublimation while maintaining high productivity.
Solution Approach 2:
The patent uses the base metal components as thermal intermediaries. The laser heats the components, which then conduct heat to the filler material, causing it to melt and flow into the joint. This indirect heating method prevents the filler from being exposed to excessive temperatures that would cause sublimation.
3Ease of manufacture
If conventional brazing methods are used, then the process is simple, but the joints lack optimal sealing and thermal fatigue strength
Solution Approach 1:
The patent replaces conventional brazing equipment with laser brazing technology, which provides precise energy delivery and better control over the thermal cycle. This substitution maintains operational simplicity while dramatically improving joint strength, sealing quality, and thermal fatigue resistance.
Solution Approach 2:
The patent optimizes thermal parameters including heating rate, peak temperature, and cooling rate through laser control. These parameter changes produce a more controlled metallurgical bond with superior properties while keeping the process straightforward through automation.
4Productivity
If automated laser brazing is implemented, then productivity and consistency improve, but device complexity increases
Solution Approach 1:
The patent employs a multi-functional integrated system where the laser source, positioning system, filler material delivery, and control software work together as a unified automated brazing platform. This universal system handles various joint types and geometries, improving productivity while managing complexity through integration rather than separate components.
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 method achieves reliable, quick, and safe brazing with optimal sealing and thermal fatigue strength, capable of handling complex geometries and high-pressure applications, reducing operator dependency and increasing efficiency.
Implementation Method 1
irradiating, with at least one laser beam (12), at least one connection end (8') of the first metal component (8) and/or at least one connection portion (9') of the second metal component (9)
Implementation Method 2
transmitting, via conduction, the thermal energy from the impact area (13) to the bead (11) in order to heat the latter
Implementation Method 3
melting the filler material, in which the thermal energy, transmitted via conduction to the bead (11), at least partially melts the filler material of the bead (11) itself
Implementation Method 4
in a manner such that the melted filler material penetrates via capillarity into said junction slit (21)
Data Source
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AI summary
A method of brazing two metal components (8, 9) comprises the following operating steps : prearranging a first metal component (8) provided with a connection end (8') and a second metal component (9) provided with a connection portion (9'), with at least the first component (8) of tubular shape, arranging the first component (8) of tubular shape with its connection end (8') facing the connection portion (9') of the second component (9), defining with the latter a junction slit (21), prearranging a bead (11) of filler material on the mouth of the junction slit (21), irradiating at least one fraction of the connection end (8') of the first component (8) and/or at least one fraction of the connection portion (9') of the second component (9) with at least one laser beam (12), defining thereon an impact area (13) that is outside with respect to the bead (11), in a manner such that the laser beam (12) does not directly hit the bead (11) itself, transmitting, via conduction, thermal energy from the impact area (13) to the bead (11), and melting the filler material, in which the thermal energy, transmitted via conduction to the bead (11), at least partially melts the filler material which consequently penetrates via capillarity into the junction slit (21).