Solder Void Insert Material for Blocking Braze Flow in Cooling Holes
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Solution Overview
Problem
Conventional insert materials used in soldering processes for gas turbines are porous and unable to effectively block braze alloy from flowing into cooling holes, leading to inefficiencies in crack repair due to their large particle size and inability to fill voids completely.
Innovation Solution
A slurry-based insert material comprising micro-sized and nano-sized metal oxide particles, such as aluminum oxide, with a binder and surfactant, is used to seal voids during soldering, ensuring the molten braze alloy only fills cracks while preventing flow into cooling holes, and can be easily removed post-soldering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If large sized particle insert material is used, then the insert material can be easily applied, but the insert material is porous and allows molten braze alloy to flow into cooling holes
Solution Approach 1:
The insert material is segmented into multiple particle sizes (micro-sized particles of 1-10 μm and nano-sized particles of 0.1-1 μm) rather than using uniform large particles. This segmentation allows the material to pack more densely and fill voids effectively while maintaining ease of application as a slurry
Solution Approach 2:
The insert material uses a composite structure combining micro-sized aluminum oxide particles (providing structural framework) with nano-sized aluminum oxide particles (filling interstices and reducing porosity). This composite approach achieves both ease of application and reliable blocking effectiveness by creating a dense, low-porosity barrier
2Ease of manufacture
If large sized particle insert material is used, then the application process is simplified, but the insert material cannot fill the entire cooling holes and creates grooves and spaces
Solution Approach 1:
The particle size distribution is segmented into micro-sized (1-10 μm) and nano-sized (0.1-1 μm) particles. The nano-sized particles fill the gaps between larger particles, enabling complete filling of cooling holes without creating grooves or spaces, while the slurry form maintains application simplicity
Solution Approach 2:
The particle size parameters are optimized with a specific ratio of nano-sized to micro-sized particles (0.1-1 μm to 1-10 μm). This parameter change enables the insert material to achieve complete filling precision while maintaining ease of manufacture through slurry application
3Ease of operation
If conventional porous insert material is used, then the material can be applied readily, but the molten braze alloy flows into cooling holes and fuses into balls
Solution Approach 1:
The composite structure of micro-sized aluminum oxide particles (providing structural integrity) and nano-sized aluminum oxide particles (reducing porosity to minimal levels) creates a dense barrier that prevents braze alloy intrusion while maintaining readiness of application as a slurry
Solution Approach 2:
The porosity parameter is changed from high (conventional) to low (minimal) through the optimized particle size distribution and ratio. This parameter change prevents braze alloy from penetrating through the insert material while the slurry form maintains ease of operation
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 insert material effectively blocks braze alloy from entering cooling holes, ensuring accurate crack repair and easy removal, even when cracks connect or extend between voids, enhancing the reliability and efficiency of the soldering process.
Implementation Method 1
the insert material is not extendable to fill the entire cooling holes. Grooves are easily appeared within the insert material and spaces are generated between the insert material and the inner surface of the cooling hole
Implementation Method 2
comprising micro-sized metal oxide particles, nano-sized metal oxide particles, and a binder
Data Source
Figure 1~3
AI summary
An insert material (18) for blocking flow of solder material into a void (12) of a component (10) during soldering operation is disclosed, which comprises micro-sized metal oxide particles; nano-sized metal oxide particles; and binder. A method for blocking flow of solder material into a void (12) of a component (10) during soldering operation is also disclosed, which comprises preparing insert material (18) in form of slurry comprising micro-sized metal oxide particles, nano-sized metal oxide particles, and binder; charging the insert material (18) into the void (12); drying the insert material (18) in the void (12) which seals the void (12); performing soldering operation; and removing the insert material (18) after soldering operation.