Solid Brazing Material for Low-Viscosity Flux Coating
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Solution Overview
Problem
Conventional brazing compositions for aluminum or aluminum alloys face issues with insufficient dispersibility of fluoride-based flux powders, inferior brazing properties, and poor application properties due to lack of moldability and viscosity control, leading to complications in production and workability.
Innovation Solution
A brazing material comprising fluoride-based flux, a solidifying agent, and an organic viscosity reducing agent, which is solid at 25°C and softens to have a viscosity of 100 Pa s or less at 150°C, allowing for excellent liquid and solid application properties, including improved moldability and reduced production line complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If liquid flux is used to remove oxides during welding, then oxide removal capability is improved, but the flux may flow when applied and requires a dry facility for solvent to solidify the coating film, causing complication of the production line and inferior workability
Solution Approach 1:
The invention changes the physical state parameter of the flux from liquid to solid by incorporating a solidifying agent (wax). This transformation maintains the oxide removal capability while eliminating the need for drying facilities, as the solidified flux coating does not require solvent evaporation. The composition is designed to remain solid at room temperature but become applicable when heated.
Solution Approach 2:
The invention uses a self-contained solid brazing composition that combines flux, brazing material, and solidifying agent in a single disposable applicatable form. This eliminates the need for separate drying facilities and complex production line equipment, as the entire flux system can be applied and solidifies in place without requiring additional processing infrastructure.
2Ease of operation
If solid brazing composition is melted and liquefied to be applied to an object to be coated, then application is simplified, but the dispersibility of fluoride-based flux powder becomes insufficient and brazing properties become inferior
Solution Approach 1:
The invention creates a composite brazing composition that integrates three distinct functional components: fluoride-based flux powder (for oxide removal), brazing material powder (for joining), and solidifying agent (for controlled solidification). This composite structure ensures that each component maintains its specific function while working together, preventing flux powder aggregation and ensuring proper dispersibility even when melted and applied.
Solution Approach 2:
The solidifying agent (wax) acts as an intermediary carrier that facilitates the uniform dispersal of fluoride-based flux powder and brazing material powder. When the composition is melted for application, the wax melts and allows thorough mixing and uniform distribution of the powder components. Upon cooling, the wax solidifies, locking the uniformly dispersed particles in place, thereby maintaining both application simplicity and brazing properties.
3Ease of operation
If solid brazing composition is applied in solid state by bringing into contact with the object to be coated, then application properties are improved, but the brazing composition does not have sufficient moldability to be formed into a desired shape
Solution Approach 1:
The invention introduces dynamic responsiveness to temperature changes into the brazing composition. The composition transitions from a solid state (at room temperature, providing moldability and shape retention) to a melted state (when heated, providing fluidity for application). This dynamic phase change allows the material to be formed into desired shapes when solid, yet still be applied effectively when melted and cooled.
Solution Approach 2:
The solidifying agent (wax) enables controlled phase transitions between solid and liquid states based on temperature. When the composition is heated above the melting point of the wax, it becomes fluid and can be applied to the workpiece. Upon cooling below the melting point, it solidifies and retains the applied shape. This phase transition mechanism provides both the moldability needed for shaping and the application properties needed for coating.
4Device complexity
If brazing composition is used without organic viscosity reducing agent, then composition simplicity is maintained, but the viscosity at 150°C exceeds 100 Pa s, resulting in poor liquid application properties
Solution Approach 1:
The organic viscosity reducing agent acts as an intermediary substance that mediates between the solidifying agent (wax) and the other components (flux powder, brazing material). It prevents excessive viscosity buildup by interfering with the crystallization network formation of the wax, thereby maintaining lower viscosity at application temperature (150°C) without requiring complex composition adjustments or additional processing steps.
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 brazing material achieves enhanced brazing properties, simplified production processes, and improved workability by maintaining low viscosity upon heating and solidifying quickly, forming a robust coating film without the need for drying, thus improving industrial productivity and application precision.
Implementation Method 1
the brazing material... being softened by heating and having the viscosity at 150° C. of 100 Pa s or less
Implementation Method 2
solidifying agent... solid at 25° C.... solidifying quickly
Data Source
AI summary
A brazing material for brazing aluminum or an aluminum alloy includes fluoride-based flux, a solidifying agent, and an organic viscosity reducing agent and is solid at 25° C.