Multilayer Metal Tube Diffusion Bonding via Nested Block Compression
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Solution Overview
Problem
Existing methods for manufacturing multilayer metal pipes often result in incomplete contact between layers, leading to discontinuous physical properties and high production costs due to the use of long, thin tubes with small wall thicknesses, which are expensive to process and connect.
Innovation Solution
A method involving the nesting of inner and outer hollow blocks, which are heated and reduced in wall thickness using a push bench process, allowing for a diffusion connection between layers without the need for additional heat treatment, using blocks as starting materials to simplify the process and achieve continuous property transition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding or soldering is used to connect tube ends, then the tubes can be joined together, but the connection is discontinuous and physical properties are not continuously transitioned
Solution Approach 1:
The patent changes the connection method from discrete welding/soldering to continuous diffusion bonding by controlling temperature and pressure parameters during the joining process, enabling continuous physical property transition across the joint
Solution Approach 2:
The patent replaces the mechanical connection method (welding/soldering) with a thermal-diffusion process where atoms interdiffuse across the interface, creating a continuous metallurgical bond without discrete connection points
2Shape
If long tubes with small wall thickness are used as starting materials, then the multilayer structure can be formed, but production costs increase and processing becomes difficult
Solution Approach 1:
The patent performs preliminary forming of the multilayer structure by nesting blocks before final tube drawing, avoiding the need to handle and process long thin-walled tubes at intermediate stages
Solution Approach 2:
The patent inverts the conventional sequence by starting with solid or hollow blocks instead of thin-walled tubes, forming the multilayer structure in a stable configuration before final tube formation
3Strength
If discrete welding or soldering points are used to connect tubes, then the tubes can be joined, but adhesion between layers is insufficient
Solution Approach 1:
The patent merges the joining operation with the forming operation by performing diffusion bonding during the tube drawing process, eliminating the need for separate welding or soldering steps
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 produces multilayer metal pipes with a seamless diffusion connection between layers, ensuring continuous physical property transition and improved adhesion, reducing production complexity and costs, and allowing for ultrasonic inspection without flaws.
Implementation Method 1
allowing for a diffusion connection between layers
Implementation Method 2
reducing the wall thickness of the nested blocks by treatment on a push bench
Data Source
Figure 1a~1b
Figure 2a~2c
Figure 3a~3b
AI summary
The method involves interlocking the inner blocks (10,16) and the outer hollow blocks (11), and heating the mutually inserted blocks. The wall thickness of the inner blocks inserted into outer blocks, is reduced by the treatment on a push bench so as to form a multilayer metal tube (1). An independent claim is included for multilayer metallic tube.