Ultrasonic Brazing Assembly for Oxide Film Removal on Complex Joints
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Solution Overview
Problem
Existing brazing methods using ultrasonic vibration are limited to joining small and simply shaped parts, and large and complex assemblies require vacuum heating or flux-based methods, which are cumbersome and limit material selection.
Innovation Solution
A brazing apparatus and method that applies ultrasonic vibration through relative motion between a stage and a pressure applier, removing oxide films on joint surfaces by colliding parts with each other, allowing for effective brazing of large and complex assemblies in a normal atmosphere without flux.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ultrasonic vibration is directly applied to the assembly for brazing, then oxide film removal and joining effectiveness are improved, but the method is limited to small and simply shaped parts only
Solution Approach 1:
The invention separates the ultrasonic vibration application from the assembly itself by using a pressure applier that transmits vibration to only the portion of the assembly being joined. This segmentation allows effective oxide film removal at the joint surface without requiring the entire complex assembly to be vibrated, thereby extending applicability to large and complex structures while maintaining joining effectiveness
Solution Approach 2:
The pressure applier serves as an intermediary between the ultrasonic vibration source and the assembly joint surface. It transmits ultrasonic vibration locally to the joint area while applying pressing force, enabling effective oxide film removal and brazing of complex assemblies without directly vibrating the entire assembly structure
2Reliability
If vacuum heating or flux-based methods are used for large and complex assemblies, then complete oxide film removal is achieved, but equipment size and complexity increase significantly
Solution Approach 1:
The invention uses ultrasonic mechanical vibration applied through the pressure applier to remove oxide films at the joint surface. This localized mechanical vibration approach achieves complete oxide film removal without requiring large vacuum heating equipment or flux-based processes, significantly reducing equipment size and complexity while maintaining reliability
Solution Approach 2:
The ultrasonic vibration is applied locally only to the joint surface area through the pressure applier, rather than treating the entire assembly. This localized approach achieves complete oxide film removal at the critical joint region without the need for large-scale equipment, reducing overall device complexity while ensuring complete oxide removal where needed
3Reliability
If flux-based brazing methods are used, then oxide film removal capability is enhanced, but material selection becomes limited and environmental concerns arise
Solution Approach 1:
The ultrasonic mechanical vibration generated by the pressure applier physically removes oxide films through high-frequency oscillation at the joint surface. This flux-free mechanical removal method enhances oxide film removal capability while maintaining broad material selection flexibility and eliminating environmental concerns associated with flux disposal
Solution Approach 2:
The invention replaces the chemical flux-based oxide removal system with a mechanical ultrasonic vibration system. This substitution removes the limitations on material selection imposed by flux compatibility requirements and eliminates environmental issues related to flux waste, while maintaining effective oxide film removal capability
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
Enables efficient brazing of large and complex assemblies by effectively removing oxide films using ultrasonic vibration, reducing equipment size and complexity, and enhancing material flexibility.
Implementation Method 1
a heater heating the assembly to a predetermined temperature that melts the brazing material
Implementation Method 2
a vibration applier applying ultrasonic vibration to at least one of the stage and the pressure applier, wherein the vibration applier removes oxide film on the joint surfaces by vibrating the stage and the pressure applier relative to each other
Implementation Method 3
generating frictional heat between each aluminum material and the brazing material to melt the brazing material
Data Source
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AI summary
A brazing apparatus (100) according to this invention includes a stage (10) supporting the assembly (AS) with the brazing materials (120) being interposed between the joint surfaces (130) of the plurality of to-be-joined materials (110); a pressure applier (20) applying a pressure to the assembly toward the stage; a heater (30) heating the assembly to a predetermined temperature that melts the brazing material in the assembly; and a vibration applier (40) applying ultrasonic vibration. The vibration applier removes oxide film on the joint surfaces of the plurality of to-be-joined materials by vibrating the stage and the pressure applier relative to each other with the assembly under the pressure having been heated to the predetermined temperature.