Chromium-Carbide Soldering Nozzle for Corrosion-Resistant Flow
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Solution Overview
Problem
Current soldering assemblies, particularly those using stainless steel nozzles, face corrosion issues due to lead-free solders and limitations in nozzle geometry, leading to sub-optimal performance and short nozzle lifetimes.
Innovation Solution
A soldering assembly with nozzles made from stacked layers of stainless steel or titanium, produced through additive manufacturing (3D printing), and diffusion-coated with chromium carbide to prevent corrosion, along with an integrated de-bridging screen and conduit for improved functionality and longevity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If stainless steel nozzles are used in lead-free soldering processes, then the nozzles can withstand high operating temperatures, but they suffer from corrosion and erosion leading to short nozzle lifetimes
Solution Approach 1:
The nozzle is constructed as a composite structure with a stainless steel substrate providing high-temperature resistance and a chromium carbide coating layer providing corrosion and erosion resistance. This multi-material approach allows the nozzle to simultaneously withstand both high temperatures and corrosive environments, resolving the contradiction between temperature resistance and reliability.
2Ease of manufacture
If nozzles are manufactured using conventional methods, then the manufacturing process is well-established, but the nozzle geometry is limited leading to sub-optimal performance
Solution Approach 1:
The invention changes the manufacturing parameter from conventional methods (such as machining or casting) to additive manufacturing (3D printing). This parameter change enables the creation of complex nozzle geometries with internal channels and integrated de-bridging screens that cannot be achieved with traditional manufacturing methods, thereby improving manufacturing precision while maintaining ease of manufacture through digital process control.
3Reliability
If the de-bridging screen is provided separately from the nozzle, then it can be positioned to prevent bridging, but the screen becomes fragile and the assembly complexity increases
Solution Approach 1:
The de-bridging screen is merged with the nozzle body to form an integral single-piece structure through additive manufacturing. This eliminates the need for separate assembly, removes the fragility associated with separate screens, and reduces overall assembly complexity while maintaining the bridging prevention function. The screen becomes an inherent part of the nozzle geometry rather than an attached component.
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 solution provides a more efficient, functional, and long-lasting soldering assembly with enhanced corrosion resistance and structural integrity, extending nozzle lifetime and reducing bridging issues in soldering processes.
Implementation Method 1
the at least one nozzle is at least partially diffusion coated with chromium carbide so as to protect the stacked layers from corrosion
Implementation Method 2
the at least one nozzle comprises a plurality of stacked layers of stainless steel or titanium, provided so as to at least partially define the at least one channel
Data Source
AI summary
A soldering assembly and a method of manufacturing a soldering assembly is disclosed. The soldering assembly includes at least one nozzle for directing solder during a soldering operation. The at least one nozzle includes an inlet for receiving a supply of solder; an outlet for dispensing solder therefrom; and at least one channel fluidly coupling the inlet to the outlet. The at least one nozzle comprises a plurality of stacked layers of stainless steel or titanium, provided so as to at least partially define the at least one channel. The at least one nozzle is at least partially diffusion coated with chromium carbide so as to protect the stacked layers from corrosion.