Nickel-Core Braze Coating Structure for Binder-Free Oxidation Control
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Solution Overview
Problem
Existing braze coating materials with a nickel core and coating suffer from residual organic binder issues, oxidation tendencies, and poor processability, leading to quality inconsistencies and increased costs.
Innovation Solution
A braze coating material with a nickel core, a coating layer containing hard particles and brazing flux, a hardened layer with a second brazing flux, and a protective silicate layer, eliminating the need for an organic binder and preventing oxidation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If nickel-based brazing filler material is used as the low melting point component, then the brazed coating has high hardness and wear resistance, but the material is hard, brittle, and poor in processability, making it difficult to process into wire-shaped or strip-shaped forms
Solution Approach 1:
The nickel-based brazing filler material is segmented into two functional parts: a nickel core providing mechanical strength and processability, and a coating layer containing the brazing filler material powder providing hardness and wear resistance. This segmentation allows each part to fulfill its specific function without compromising the other.
Solution Approach 2:
The invention creates a composite structure combining a nickel core with a coating layer containing hard particles, binder, and brazing filler material. This composite material approach integrates the ductility and processability of nickel with the hardness and wear resistance of the brazing filler material, resolving the contradiction between strength and manufacturability.
2Ease of manufacture
If powdered brazing filler material is used with organic binder, then the material can be processed and applied, but the organic binder residue during use affects the quality of the braze coating
Solution Approach 1:
The harmful organic binder is extracted and replaced with an inorganic binder system. The coating layer uses a water-based slurry containing inorganic binder materials that do not produce harmful residues during brazing, eliminating the quality issue while maintaining processability through the slurry application method.
3Ease of manufacture
If powdery metal particles are exposed outside the coating, then the brazing filler material can be applied, but the particles are easily oxidized and deteriorated during transportation and storage
Solution Approach 1:
A protective coating layer is formed around the nickel core, creating a protective shell that prevents oxidation of the metal particles during transportation and storage. This thin film structure maintains the applicability of the brazing material while providing the necessary protection against environmental degradation.
4Reliability
If brazing flux is continuously added during braze coating procedure, then oxidation is prevented and wetting is facilitated, but work efficiency is reduced and cost increases
Solution Approach 1:
The brazing flux is incorporated into the coating layer during the manufacturing process, before the actual brazing operation. This preliminary incorporation eliminates the need for continuous addition of flux during the brazing procedure, improving work efficiency while maintaining oxidation protection and wetting properties.
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 solution provides a stable, oxidation-resistant braze coating with strong adhesion, reduced moisture absorption, and improved welding quality, facilitating automated production and reducing residual carbon content.
Implementation Method 1
The nickel core is metallic nickel having a roughened surface
Implementation Method 2
it is necessary to continuously add a brazing flux during the braze coating procedure, which results in low work efficiency and easily causes a large waste of the brazing flux and higher cost
Implementation Method 3
to facilitate wetting and spreading of the brazing filler material on the surfaces of the hard alloy/diamond particles and the base material
Implementation Method 4
The braze coating method involves making a brazed coating metallurgically bonded with the base material, wherein the bonding strength is much higher than the mechanical bonding in the thermal spraying
Implementation Method 5
the brazed coating has a smooth surface and high construction accuracy, and can reach the required accuracy by being less processed
Data Source
AI summary
A braze coating material with a nickel core and a coating, a preparation method thereof, and a braze coating method are provided. The braze coating material with a nickel core and a coating requires no binder and has strong adhesion ability, and includes the nickel core, a coating layer, a hardened layer, and a protective layer sequentially from inside to outside. The nickel core is metallic nickel having a surface subjected to a roughening treatment. The coating layer is a first brazing flux layer including hard particles, a first brazing flux, and a brazing filler metal powder. The hardened layer contains a second brazing flux and is covered with the protective layer mainly composed of a silicate.