Sequential Plated Brazing Layers for Low-Temperature Joining
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Solution Overview
Problem
Existing joining methods using brazing materials are costly and inefficient, particularly when multiple materials are involved, as they require complex plating baths and high heat-resistant temperatures, which can damage certain materials.
Innovation Solution
A joining method and system that uses a multi-layer brazing approach, where different materials are plated sequentially on a member and then melted to form a eutectic joining layer, reducing the need for mixed plating liquids and allowing for lower heat-resistant temperatures, thereby minimizing equipment costs and preventing material damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single plating bath containing mixed metal alloy is used for brazing, then the joining process can be simplified, but the equipment cost increases due to the complexity of maintaining molten metal alloy baths
Solution Approach 1:
The plating process is segmented into multiple sequential steps, each using a different plating bath for a specific layer. Instead of one complex mixed alloy bath, the invention uses separate baths for each material layer (e.g., first plating bath for Cu, second plating bath for Ag), simplifying the composition requirements of each individual bath while achieving the desired multi-layer structure.
Solution Approach 2:
The brazing layers are prepared in advance through sequential plating operations before the actual joining process. The multi-layer structure is built up beforehand on the workpiece surfaces, allowing the subsequent joining process to simply melt and bond the pre-prepared layers without requiring complex real-time alloy mixing.
2Strength
If high heat-resistant temperatures are used for melting the brazing material, then the joining strength is improved, but the materials being joined may be damaged
Solution Approach 1:
The invention changes the chemical composition parameters of the brazing layers to create a eutectic system with a lower melting point. By selecting specific materials and ratios (e.g., Cu-Ag system with appropriate proportions), the melting temperature is reduced from typical high-temperature brazing ranges to a lower temperature that still provides strong joints but does not damage temperature-sensitive base materials.
Solution Approach 2:
The brazing interface is designed as a composite multi-layer structure with different materials (e.g., Cu layer, Ag layer, Au layer) that work together to achieve both strong bonding and low melting temperature. The composite structure allows each layer to contribute its beneficial properties while the overall system melts at a controlled lower temperature.
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 method effectively joins materials with reduced equipment costs and lower heat requirements, ensuring strong bonds while avoiding material damage from high temperatures.
Implementation Method 1
providing a first brazing layer on the first member by plating; and providing a second brazing layer on the first brazing layer by plating
Implementation Method 2
melting the joining layer to join the first member and the second member which are arranged to oppose each other
Data Source
AI summary
A joining method for joining a first member and a second member is provided. The joining method includes a step of providing a first brazing layer on the first member by plating, a step of providing a second brazing layer on the first brazing layer by plating, a step of arranging the first member and the second member to oppose each other across the first brazing layer and the second brazing layer, and a step of melting the first brazing layer and the second brazing layer to join the first member and the second member which are arranged to oppose each other.