Self-Brazing Alloy Strip for Titanium Brazing
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Solution Overview
Problem
Traditional titanium brazing processes are complex, time-consuming, and costly due to the need for expensive vacuum furnaces and poor contact between base metal and filler material, leading to low yield and poor braze quality.
Innovation Solution
A self-brazing alloy strip is created by bonding multiple layers of metals, such as titanium, copper, and nickel, which form a braze alloy during brazing, eliminating the need for separate braze filler layers and allowing for in-situ braze formation, using techniques like cold roll bonding to ensure intimate contact and controlled atmosphere brazing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional brazing processes are used with separate braze filler layers, then the brazing process can be performed, but the assembly operation becomes complicated and time-consuming with poor contact between base metal and filler material
Solution Approach 1:
The invention merges the base metal and filler material into a single integrated brazing strip structure. The multi-layer strip combines titanium base metal layers with copper and nickel filler material layers, eliminating the need for separate stacking operations. This integration ensures intimate contact between base metal and filler material while simplifying the assembly process to a single component placement operation.
Solution Approach 2:
The brazing strip is pre-fabricated with the filler material already positioned in intimate contact with the base metal layers. This preliminary preparation of the brazing material eliminates the need for complex assembly operations during the brazing process, as the filler material is already in the correct position and contact configuration before the brazing operation begins.
2Reliability
If traditional brazing processes are used with individual stacking of base material and filler metal, then the brazing can be performed, but the assembly time increases significantly
Solution Approach 1:
The invention combines multiple layers of base metal and filler material into a single pre-assembled brazing strip. This merging of materials into one integrated component eliminates the time-consuming individual stacking operations while maintaining the intimate contact necessary for high-quality brazing results.
Solution Approach 2:
The brazing strip is prepared in advance with all filler material layers positioned between the base metal layers. This preliminary action of pre-positioning the filler material eliminates the need for time-consuming assembly operations during the actual brazing process, significantly reducing assembly time while ensuring proper contact for reliable brazing quality.
3Reliability
If traditional brazing processes are used with individual stacking operations, then the brazing can be performed, but yield losses increase due to poor contact and oxidation
Solution Approach 1:
The invention integrates the base metal and filler material into a single brazing strip structure, ensuring intimate contact between layers. This integration prevents the poor contact that leads to oxidation and braze failures, thereby reducing yield losses while maintaining high braze quality.
Solution Approach 2:
The brazing strip is pre-fabricated with filler material layers in intimate contact with base metal layers before the brazing operation. This preliminary preparation ensures proper contact configuration is established beforehand, preventing oxidation and braze failures that occur with poor contact during traditional stacking operations, thus reducing yield losses.
4Reliability
If traditional brazing processes are used with separate braze components, then the brazing can be performed, but production costs increase due to expensive vacuum furnaces and complex operations
Solution Approach 1:
The invention combines base metal and filler material into a single brazing strip component, simplifying the overall brazing system. This integration reduces the complexity of assembly operations and enables the use of less expensive furnaces, thereby reducing production costs while maintaining reliable braze quality through the intimate contact ensured by the integrated structure.
5Reliability
If traditional brazing processes are used with intermittent braze foil stacking, then the brazing can be performed, but the process becomes difficult to automate
Solution Approach 1:
The invention merges multiple layers of base metal and filler material into a single pre-assembled brazing strip. This integration transforms the brazing input from a complex multi-step stacking process into a single component placement operation, making the process easily automatable while maintaining the intimate contact necessary for reliable braze quality.
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 reduces production costs, simplifies the brazing process, and improves braze quality by ensuring intimate contact between base and filler metals, enabling the use of less expensive furnaces and increasing yield in high-volume manufacturing applications like heat exchangers and honeycomb structures.
Implementation Method 1
using techniques like cold roll bonding to ensure intimate contact
Implementation Method 2
A self-brazing alloy strip is created by bonding multiple layers of metals, such as titanium, copper, and nickel, which form a braze alloy during brazing
Implementation Method 3
allowing extracting desired braze constituent elements from the base metal to perform an in-situ braze alloy during brazing
Data Source
AI summary
A method for producing an alloy self-brazing strip. In an aspect, a process is used to generate a multi-layer alloy strip made up of at least one base layer of with a least another layer of material, that when both the material and base layer are brazed, form an alloy. In an aspect, the other layer of material can include a metal. The base layer can include titanium or a titanium alloy.