Sinter-Brazed Powder Metal to Wrought Steel Joining With Martensite Hardening
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Solution Overview
Problem
Manufacturing metal parts that require the formation of martensite, brazing, and sintering in a single step while integrating powder metal components with wrought steel stampings poses challenges in achieving desired performance characteristics and cost-effectiveness.
Innovation Solution
A method involving the use of a powder metal sinterbraze/sinter hard steel component and a wrought steel stamping component, where the components are affixed with a brazing filler metal and sintered together under specific temperature and cooling conditions, followed by tempering to produce a desired metal part with enhanced toughness and reduced brittleness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If powder metal components are attached to wrought steel stampings through separate brazing and sintering processes, then the components can be joined and hardened, but the manufacturing process becomes complex and time-consuming
Solution Approach 1:
The patent combines brazing and sintering operations into a single integrated process. The green compact is placed in direct contact with the wrought steel component, and both are heated simultaneously in one furnace cycle. The brazing filler metal melts and flows into the interface between the green compact and steel component, while the green compact undergoes sintering at the same time, achieving both joining and hardening in one step rather than through separate sequential operations.
Solution Approach 2:
The single heating furnace serves multiple functions: it acts as both a brazing furnace and a sintering furnace. The same thermal field and heating cycle accomplish both the brazing of the joint and the sintering/hardening of the powder metal component, eliminating the need for separate specialized equipment and process steps.
2Reliability
If powder metal components are attached to wrought steel stampings through separate brazing and sintering processes, then the components can be joined and hardened, but the manufacturing time increases
Solution Approach 1:
The patent combines brazing and sintering operations into a single integrated process. The green compact is placed in direct contact with the wrought steel component, and both are heated simultaneously in one furnace cycle. The brazing filler metal melts and flows into the interface between the green compact and steel component, while the green compact undergoes sintering at the same time, achieving both joining and hardening in one step rather than through separate sequential operations.
Solution Approach 2:
The heating process continues simultaneously to perform multiple useful actions: heating the brazing filler metal to its melting point for joint formation, sintering the green compact to develop strength, and hardening the powder metal component to achieve desired mechanical properties. All these beneficial transformations occur continuously during the same time period without interruption or cooling between steps.
3Adaptability or versatility
If powder metal components are used to achieve intricate designs, then design flexibility is improved, but the ability to form martensite and achieve desired performance characteristics becomes difficult
Solution Approach 1:
The patent utilizes changes in thermal parameters during the heating cycle to achieve martensite formation in the powder metal component. By controlling the heating rate, peak temperature, and especially the cooling rate after heating, the microstructure of the powder metal part transforms to form martensite, which provides the desired strength and performance characteristics while maintaining the intricate design capabilities of powder metal manufacturing.
Solution Approach 2:
The final assembly represents a composite structure combining the powder metal component (with martensitic microstructure achieved through controlled heating and cooling) with the wrought steel component, joined by the brazed interface. This composite construction allows each material to contribute its advantageous properties while achieving overall performance that neither material could provide alone.
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 allows for the formation of metal parts with improved toughness and reduced brittleness by integrating powder metal and wrought steel components in a single sintering step, achieving desired performance characteristics while maintaining cost-effectiveness.
Implementation Method 1
affixing the powder metal sinter hard steel component and the wrought steel stamping component together with a brazing filler metal being alloyed at the interface between the powder metal sinter hard steel component and the wrought steel stamping component
Implementation Method 2
sinter brazing/sinter hardening the powder metal hard steel component and the wrought steel stamping component together
Implementation Method 3
tempering the in-process metal part to produce the desired metal part
Data Source
AI summary
This invention discloses a method of manufacturing a desired metal part which comprises (1) providing an powder metal sinterbraze hard steel component and a wrought steel stamping component; (2) affixing the powder metal hard steel component and the wrought steel stamping component together with a brazing filler metal being alloyed at the interface between the powder metal hard steel component and the wrought steel stamping component; (3) sinter brazing the powder metal hard steel component and the wrought steel stamping component together to produce an in-process metal part; and (4) tempering the in-process metal part to produce the desired metal part.