Localized Brazing Heating for Fuel Injector-Manifold Joints
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Solution Overview
Problem
Conventional joining techniques, such as brazing and welding, are inefficient and time-consuming, especially in applications like gas turbine engines, where precise and rapid assembly of fuel injectors to manifolds is required without altering the material properties of the components.
Innovation Solution
A method involving local heating of the joint location using directed heat sources like lasers or electron beams to melt braze material while maintaining the temperature of remote portions of the work pieces, allowing for precise and efficient braze joint formation without the need for o-ring seals or extensive oven cycles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional brazing using oven heating is used, then the entire assembly can be heated uniformly, but the heating time is considerable and material properties of remote portions are altered
Solution Approach 1:
The patent applies localized heating only to the joint location where braze is needed, rather than heating the entire assembly. This is achieved by directing heat sources (laser, electron beam, or focused microwave) precisely at the joint location, melting the braze material locally while keeping remote portions of the work pieces at their original temperature, thus reducing heating time and preserving material properties.
Solution Approach 2:
The heating process is segmented into localized zones rather than uniform heating. The heat is applied in discrete focal points at specific joint locations, allowing independent control of temperature and time for each joint, while other areas remain unaffected.
2Temperature
If conventional brazing using oven heating is used, then the entire assembly is heated, but material properties of remote portions are altered
Solution Approach 1:
The heating is localized to only the joint location where braze material is present. Directed heat sources concentrate energy precisely at the joint, melting the braze while maintaining the temperature of remote portions of the work pieces below their material property alteration thresholds, thus preserving the stability of the work piece composition.
3Productivity
If directed heat sources are used for local heating, then heating time is reduced, but precision in controlling heat application is required
Solution Approach 1:
The patent incorporates temperature monitoring at the joint location to provide feedback control of the directed heat source. This allows real-time adjustment of heating parameters to maintain precise temperature control, ensuring the braze melts at the correct temperature while preventing overheating of the work pieces, thus achieving both high productivity and manufacturing precision.
4Loss of time
If localized heating is used, then remote portions remain at original temperature, but the heating must be precisely controlled
Solution Approach 1:
The patent replaces conventional mechanical oven heating systems with directed energy sources (laser, electron beam, or focused microwave). These directed energy sources inherently provide localized heating with built-in spatial control, reducing the need for complex external heating control mechanisms while achieving rapid and precise temperature control at the joint location.
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 method enables quicker and more precise joining of fuel injectors to manifolds, allowing for higher fuel temperatures and reducing material property alterations, while eliminating the need for o-ring seals and minimizing batch failures.
Implementation Method 1
The directed heat source can include at least one of a laser, electron beam, and/or focused microwave beam
Implementation Method 2
The directed heat source can include at least one of a laser, electron beam, and/or focused microwave beam
Implementation Method 3
The directed heat source can include at least one of a laser, electron beam, and/or focused microwave beam
Implementation Method 4
applying local heating to the joint location of the two work pieces until braze melting temperature is achieved to melt the braze
Data Source
Figure 1
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AI summary
A method comprising applying braze to a joint location (110) of two work pieces and applying local heating to the joint location (110) of the two work pieces until braze melting temperature is achieved to melt the braze while maintaining temperature of more remote portions of each work piece. The method includes reducing heating of the braze to form a braze joint joining the joint location (110) of the two work pieces.