Laser-Clad Braze Preform Placement for Leak-Free Joints
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Solution Overview
Problem
Conventional brazing methods for components that undergo high heat, such as fuel injectors and heat exchangers, are inconsistent and prone to high scrap rates due to manual application of braze material, leading to issues like leakage and excess material blocking passages, as they lack precision in applying the correct amount of braze to the right locations.
Innovation Solution
A method involving laser cladding of a braze filler adjacent to a void between components, allowing precise control over the location and amount of braze material by melting and flowing it into the void during heating, using materials like bronze-based or steel-based alloys, to form a strong and controlled braze joint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual application of braze paste is used, then the process is simple, but the manufacturing precision and consistency deteriorate
Solution Approach 1:
The patent replaces manual mechanical application of braze paste with automated laser cladding technology. The laser system precisely deposits braze filler material onto the component surfaces adjacent to the void, eliminating manual variability and achieving consistent, accurate placement without requiring masking or manual positioning skills.
Solution Approach 2:
The patent changes the physical state and delivery method of the braze material from paste form requiring manual spreading to laser-clad filler material that is automatically deposited in controlled quantities. This parameter change enables precise control over the amount and location of braze material through laser process parameters rather than manual technique.
2Manufacturing precision
If braze rings are used, then the manufacturing precision improves, but the device complexity and ease of operation worsen
Solution Approach 1:
The patent eliminates the need for mechanical braze ring positioning by substituting with automated laser cladding. The laser system directly deposits filler material at the precise location adjacent to the void, removing the complexity of manually positioning and securing braze rings while maintaining high placement precision.
Solution Approach 2:
The laser cladding process performs preliminary deposition of braze filler material in the exact position and quantity needed before the brazing operation. This preliminary action eliminates the need for subsequent positioning adjustments or masking operations that would be required with braze rings.
3Stability of the object's composition
If conventional weld balls are used for tack welding, then the components are held in position, but the productivity deteriorates due to extra removal process
Solution Approach 1:
The patent extracts and eliminates the unnecessary step of using and subsequently removing tack weld balls. The laser cladding process directly applies braze filler material that serves both as positioning aid and as the final braze joint material, removing the extraneous removal operation and improving productivity.
Solution Approach 2:
The patent merges the functions of tack welding and final brazing into a single laser cladding operation. The braze filler material deposited by laser serves dual purposes: holding components in position during heating and forming the final braze joint, eliminating the need for separate tack weld ball application and removal steps.
4Reliability
If too much braze material is applied, then the reliability improves by preventing leakage, but the harmful factors increase due to blockages
Solution Approach 1:
The laser cladding process applies braze filler material with local precision only at the specific locations adjacent to the void where sealing is needed. This localized deposition ensures adequate braze material for preventing leakage while avoiding excess material that could block fuel or air passages in atomizers and other components.
Solution Approach 2:
The laser cladding process provides precise control over braze material deposition through feedback control of laser parameters and deposition rate. This ensures the correct amount of filler material is applied to fill the void completely without over-deposition that could cause blockages, achieving optimal sealing integrity.
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 enhances precision and reduces scrap rates by ensuring accurate placement and quantity of braze material, minimizing leakage and blockages, while providing a strong metallurgical bond with minimal heat-affected zones.
Implementation Method 1
Depositing the braze filler can include laser cladding the braze filler to the first and/or second components adjacent the void
Implementation Method 2
The first and second components are heated to melt the braze filler and draw the braze filler into the void
Implementation Method 3
heating the first and second components to melt the braze filler and draw the braze filler into the void
Implementation Method 4
A braze joint is formed between the first and second components by cooling the braze filler
Data Source
Figure 1~2
Figure 3~6
AI summary
A method of manufacturing includes depositing a braze filler (110) adjacent to a void (116) between a first component (112) and a second component (114) thus holding the components in position before brazing. The first and second components are heated to melt and flow the braze filler into the void. A braze joint (118) is formed between the first and second components by cooling the braze filler. Depositing the braze filler can include laser cladding the braze filler to the first and/or second components adjacent the void. The method also optionally includes welding the first and second components in position with the braze filler adjacent to the void. The braze filler may be deposited as a powder, cold spray, melted brazed filament, spherical ball or any other suitable form.