Vapor-Deposited Diffusion Bonding for Clean Monolithic Joints

Solution Overview

Problem

The multi-step method of manufacturing dual-walled components through diffusion bonding is costly and prone to contamination and long processing times, especially when using braze materials, which hampers efficient production and repair of gas turbine engine components.

Innovation Solution

A vapor deposition method is employed to apply a temperature suppressant coating onto surfaces, including discontinuous and damaged areas, followed by assembly and diffusion bonding at elevated temperatures and compressive forces, reducing processing time and contamination risks.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If braze materials are used to facilitate diffusion bonding, then bonding is improved, but processing time increases and contamination risk increases

Engineering Contradiction:

Improvebonding qualityVSAvoidprocessing time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The coating is applied to the surface before assembly, preparing the bonding interface in advance. This preliminary preparation eliminates the need for lengthy in-process braze material application and cleaning steps, reducing total processing time while ensuring consistent bonding quality

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The harmful cleaning step is extracted and eliminated from the process. By pre-applying the coating before assembly, there is no braze material residue to clean from unwanted areas, removing this time-consuming and contamination-prone step entirely

Inventive Principle:

Principle #2Taking out (Extraction)

2Reliability

If braze materials are used to facilitate diffusion bonding, then bonding is improved, but contamination risk increases

Engineering Contradiction:

Improvebonding qualityVSAvoidcontamination

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The coating is applied to the surface before assembly, preparing the bonding interface in advance. This preliminary preparation eliminates the need for lengthy in-process braze material application and cleaning steps, reducing total processing time while ensuring consistent bonding quality

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The harmful cleaning step is extracted and eliminated from the process. By pre-applying the coating before assembly, there is no braze material residue to clean from unwanted areas, removing this time-consuming and contamination-prone step entirely

Inventive Principle:

Principle #2Taking out (Extraction)

3Reliability

If multiple furnace steps are used for diffusion bonding, then bonding quality is improved, but device complexity increases

Engineering Contradiction:

Improvebonding qualityVSAvoidprocess complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Multiple separate furnace steps (coating application, assembly, bonding, cleaning) are merged into a single integrated vapor deposition and bonding process. The coating is deposited directly onto the surface in the same vacuum chamber where assembly and bonding occur, eliminating the need for multiple furnace cycles and reducing process complexity

Inventive Principle:

Principle #5Merging (Combining)

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 enables efficient and contamination-free diffusion bonding of metal alloy components, producing a monolithic interface suitable for high-temperature applications, such as in gas turbine engines, with reduced processing time and improved surface preparation.

Implementation Method 1

depositing a coating from a vapor comprising a temperature suppressant element onto a surface of a first component comprising a metal alloy, thereby forming on the surface a vapor deposited coating comprising the temperature suppressant element

Methodology Applied

Scientific EffectVapor deposition: Physical Vapour Deposition

Implementation Method 2

Diffusion bonding is a solid-state bonding method where elevated temperatures and typically high pressures are employed to obtain diffusion of atoms between mating components, allowing for formation of a thermally-stable metallurgical bond

Methodology Applied

Scientific EffectDiffusion: Diffusion

Data Source

PatentUS11612947B2Method of diffusion bonding utilizing vapor deposition

Publication Date: 2023.03.28 ROLLS ROYCE CORP

AI summary

A method of diffusion bonding utilizing vapor deposition comprises depositing a coating from a vapor comprising a temperature suppressant element onto a surface of a first component comprising a metal alloy, thereby forming a vapor deposited coating comprising the temperature suppressant element; assembling the first component with a second component comprising a mating surface to form an assembly, the vapor deposited coating contacting the mating surface; and exposing the assembly to a bonding temperature and a compressive force, thereby diffusion bonding the first component to the second component and forming a monolithic third component.