Pre-Sintered Braze Reinforcement for Complex Pressure Vessel Geometries
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Solution Overview
Problem
Pressure vessels, particularly those in high-temperature mechanical systems like gas turbine engines, face challenges in effectively reinforcing complex geometries to withstand increased stresses during operation, as existing methods often result in porosity, deformation, and reduced bond strength.
Innovation Solution
The use of pre-sintered preform (PSP) braze material, comprising a mixture of low-melt and high-melt powders, is applied to the substrate, where the low-melt powder softens and melts to conform to the substrate's contour, forming a strong bond while reducing porosity and deformation, and is then cooled to create a reinforced component with improved mechanical and oxidation resistance properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional braze materials are used for reinforcing pressure vessels, then the reinforcement can be applied to complex geometries, but porosity and deformation occur reducing bond strength
Solution Approach 1:
The patent changes the physical-chemical parameters of the braze material by using a pre-sintered preform with controlled porosity and composition rather than traditional solid or powder braze materials. This parameter change allows the material to flow and conform to complex geometries while maintaining structural integrity and reducing defects
Solution Approach 2:
The pre-sintered preform is prepared in advance with specific structural characteristics before being applied to the pressure vessel. This preliminary action of creating a preformed reinforcement structure with controlled porosity and composition enables the material to properly bond to complex geometries without developing porosity or deformation during the brazing process
2Strength
If reinforcement is applied to withstand increased stresses, then mechanical strength improves, but manufacturing time and costs increase
Solution Approach 1:
The pre-sintered preform is manufactured in advance with optimized structural characteristics, allowing it to be directly applied to the pressure vessel without additional processing steps. This preliminary preparation reduces manufacturing time and costs while maintaining the mechanical strength improvements
Solution Approach 2:
By changing the parameters of the braze material to use a pre-sintered preform with specific porosity and composition, the patent achieves better mechanical strength with a more efficient manufacturing process, reducing both time and costs compared to traditional reinforcement methods
3Manufacturing precision
If pre-sintered preform braze material is used, then bond strength and dimensional accuracy improve, but the process requires precise temperature control
Solution Approach 1:
The pre-sintered preform has been pre-characterized with specific thermal and structural parameters that enable predictable behavior during brazing. This parameter optimization allows the material to achieve high dimensional accuracy while working within manageable temperature control parameters
Solution Approach 2:
The patent replaces complex real-time adjustment mechanisms with a pre-sintered preform that has inherent structural stability. This substitution reduces the need for complex temperature control systems while maintaining high manufacturing precision
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 enhances the mechanical strength and high-temperature oxidation resistance of pressure vessel components, reduces manufacturing time and costs, and improves bond strength and dimensional accuracy compared to traditional braze materials, making it suitable for reinforcing critical areas like armpit patches in gas turbine engines.
Implementation Method 1
heating the PSP reinforcement to soften or melt at least one constituent metal or alloy of the low-melt powder
Implementation Method 2
heating the PSP reinforcement to soften or melt at least one constituent metal or alloy of the low-melt powder
Implementation Method 3
the PSP reinforcement is configured to conform to a contour of the surface of the substrate
Implementation Method 4
the PSP reinforcement is configured to conform to a contour of the surface of the substrate
Implementation Method 5
The PSP reinforcement is formed on the surface of the substrate by brazing
Implementation Method 6
cooling the PSP reinforcement to define a reinforced component
Data Source
AI summary
The disclosure describes assemblies, systems, and techniques for reinforcing complex geometries of pressure vessels using a pre-sintered preform (PSP) braze material that includes a low-melt powder and a high-melt powder. An example technique includes positioning a PSP reinforcement on a surface of a substrate. The technique includes heating the PSP reinforcement to soften or melt at least one constituent metal or alloy of the low-melt powder. During heating, the PSP reinforcement is configured to conform to a contour of the surface of the substrate. The technique also includes cooling the PSP reinforcement to define a reinforced component.