Wicking Structure for Precise Braze Flow Control in Nozzles
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Solution Overview
Problem
Conventional brazing techniques face challenges in controlling the flow of braze alloy, leading to imprecise filling of narrow passages and potential plugging of intricate features, which limits the design of fuel and air flow passages in nozzles.
Innovation Solution
A method involving a wicking structure that provides flow communication from a braze reservoir to a joint location, allowing braze to flow through the structure upon heating, ensuring precise braze placement and avoiding unnecessary braze accumulation in other areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional brazing techniques are used, then the braze alloy can be applied to components, but the braze flow becomes imprecise and may plug intricate passages
Solution Approach 1:
A wicking structure is introduced as an intermediary component between the braze alloy source and the joint location. This wicking structure controls and directs the flow of molten braze alloy, preventing it from flowing imprecisely or plugging intricate passages while ensuring it reaches the desired joint location.
Solution Approach 2:
The wicking structure utilizes porous material properties to control braze alloy flow. The porous structure allows the molten braze to be absorbed and transported through capillary action, providing precise flow control and preventing uncontrolled spreading that would cause plugging of narrow passages.
2Manufacturing precision
If braze alloy is applied in close proximity to the joint location, then flow control improves, but design flexibility of flow passages is limited
Solution Approach 1:
The wicking structure serves as a mediator that decouples the braze alloy source location from the joint location. This allows the braze reservoir to be positioned in optimal locations for structural integrity while the wicking structure delivers the braze precisely to the joint, thereby maintaining both flow control and design flexibility.
Solution Approach 2:
The wicking structure introduces a new spatial dimension for braze transport. Instead of relying on direct proximity or gravity-driven flow, the braze is transported through a controlled pathway (the wicking structure) that can be routed through three-dimensional space, enabling flexible passage design while maintaining precise flow control.
3Ease of manufacture
If braze is applied as paste, wire ring, or sheet shim, then the braze can be positioned on components, but the braze may not flow to the desired area in the quantity needed
Solution Approach 1:
The wicking structure acts as a mediator between the braze alloy source and the joint location, ensuring that the correct quantity of braze is delivered. It absorbs and transports the molten braze through capillary action, providing controlled delivery in the precise quantity needed for proper joint formation.
Solution Approach 2:
The system utilizes changes in physical parameters during the brazing process. The wicking structure exploits changes in viscosity, surface tension, and capillary pressure as the braze melts and flows, enabling precise control over the quantity of braze delivered to the joint location.
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 approach enhances control over braze flow, ensuring it reaches the intended joint location while keeping other passages clear, offering improved design flexibility and performance in nozzle components.
Implementation Method 1
A wicking structure provides flow communication from the braze reservoir to the joint location
Implementation Method 2
applying heat to the braze to flow the braze from the reservoir through the wicking structure
Data Source
AI summary
A method of joining includes applying braze to a braze reservoir in a first component. A second component is engaged to the first component, wherein a joint location is defined between the first and second components. A wicking structure provides flow communication from the braze reservoir to the joint location. The method also includes joining the first and second components together at the joint location by applying heat to the braze to flow the braze from the reservoir through the wicking structure to the joint location to form a braze joint at the joint location.