Low-Melt Coating Bonding for Dissimilar Metal Components
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Solution Overview
Problem
Existing methods for connecting components made of different metallic materials, such as welding and resistance soldering, often result in warpage, surface deformation, and difficulty in forming durable connections, especially with thin-walled components, and struggle to create a defined two-dimensional connecting layer.
Innovation Solution
A method involving local heating of a coating with a lower melting temperature than the components to a connecting temperature above its melting point but below that of the components, followed by cooling to form a fixed, two-dimensionally defined connecting layer without additional materials, using tools like welding guns or forming presses for precise control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding processes are used to connect components of different metallic materials, then connection is achieved, but warpage and surface deformation occur especially in thin-walled components
Solution Approach 1:
The invention changes the temperature parameter by using a coating material with a lower melting point than the base metals. This allows the connecting layer to be formed at a temperature below the melting point of the components, preventing warpage and surface deformation while still achieving durable connection.
Solution Approach 2:
The coating on the component surfaces acts as an intermediary material that facilitates connection between different metallic materials. This intermediate layer melts and forms a connecting layer that bonds the components together without requiring the base metals to reach their melting points, thus avoiding thermal damage.
2Strength
If resistance soldering is used with soldering alloy, then connection is achieved, but the size and arrangement of connecting points are influenced by the mass and flow behavior of the soldering alloy
Solution Approach 1:
The coating already present on the component surfaces serves as the connecting material, eliminating the need to introduce and position separate soldering alloy. The coating's location and amount are predetermined by the component manufacturing process, enabling precise control over the connecting layer's size and arrangement without being influenced by material flow behavior.
3Strength
If high temperature welding is used to connect different metallic materials, then connection is achieved, but the surface of components is deformed or discolored
Solution Approach 1:
The invention changes the temperature parameter by utilizing a coating material with a lower melting point than the base metals. This enables the connection process to occur at temperatures below the melting point of the components, preventing surface deformation and discoloration while still achieving durable connection through the melted coating material.
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 prevents warpage and surface damage while enabling the formation of a precise, durable connecting layer without the need for additional materials, suitable for thin-walled components and various geometric shapes, ensuring high-quality connections.
Implementation Method 1
locally heating the coating in a region which is predetermined for the production of the defined connecting layer to a connecting temperature which lies above the melting temperature of the third material and lies below the melting temperature of the first material and below the melting temperature of the second material
Implementation Method 2
the coating is at least partially melted in the region of the defined connecting layer
Implementation Method 3
cooling the at least partially melted coating in order to, during the solidification of said coating, form the connecting layer
Implementation Method 4
during the solidification of said coating, form the connecting layer
Data Source
AI summary
A method produces at least one defined connecting layer between two components, wherein the first component is produced from a first metallic material and the second component is produced from a second metallic material and the first and/or second component has a coating of a third metallic material, the melting temperature of which is lower than the melting temperature of the first and second materials. In this case, the coating of at least one of the components is heated locally to a connecting temperature, which lies above the melting temperature of the third material and lies below the melting temperature of the first material and below the melting temperature of the second material, and is cooled down in order to form a defined connecting layer when the coating solidifies.