SYSTEMS AND METHODS OF MANUFACTURING A BRAZING ALLOY COMPONENT

Abstract

Systems and methods of manufacturing a brazing alloy component such that the brazing alloy component has sufficient ductility to be formed into a ring-shaped member.

Description

TECHNICAL FIELD

Systems and methods are provided for manufacturing brazing alloy components, and particularly to manufacturing brazing alloy components having sufficient ductility to form a ring-shaped member.

BACKGROUND

Conventional systems and methods for manufacturing alloys used to braze ferrous and non-ferrous metals and alloys have been successful for many years. However, while such conventional methods provide techniques for manufacturing brazing alloys, these systems and methods have not provided brazing alloys capable of forming ring-shaped members to be used in various brazing applications.

SUMMARY

In accordance with one embodiment, a method for manufacturing a brazing alloy component comprises extruding a billet to form an elongated member, drawing the elongated member through a die mechanism, and cooling the elongated member to form the alloy component. The billet comprises an alloy material consisting essentially of phosphorus, silicon, copper and at least one of tin and antimony. The alloy component is sufficiently ductile such that the alloy component can be formed into a ring-shaped member.

In accordance with another embodiment, a method of manufacturing a brazing alloy component comprises means for extruding a billet to form an elongated member, means for drawing the elongated member through a die, means for cooling the elongated member to form an alloy component, and means for forming a ring-shaped member from the alloy component. The billet comprises an alloy material consisting essentially of phosphorus, silicon, copper and at least one of tin and antimony.

In accordance with yet another embodiment, a system of manufacturing a brazing alloy component comprises an extrusion device, a heating mechanism, a drawing device and a cooling mechanism. The extrusion device is configured to extrude a billet to form an elongated member. The billet comprises an alloy material consisting essentially of phosphorus, silicon, copper and at least one of tin and antimony. The elongated member has a predetermined thickness. The heating mechanism is configured to heat the elongated member having exited the extrusion device. The drawing device is configured to receive the elongated member from the heating mechanism and modify the elongated member. The modified elongated member has a smaller thickness than the predetermined thickness. The cooling mechanism is configured to cool the elongated member exiting the drawing device to form an alloy component.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing out and distinctly claiming the invention, it is believed that the same will be better understood from the following description taken in conjunction with the accompanying in which:

FIG. 1 illustrates a process flow diagram of a system for manufacturing alloy components;

FIG. 2A illustrates a side elevational view of an extruder die;

FIG. 2B illustrates a cross-sectional view of the extruder die taken along section lines 2B-2B in FIG. 2A;

FIG. 3 illustrates an embodiment of drawing and annealing stations;

FIG. 4 illustrates a cross-sectional view of an embodiment of a drawing die;

FIG. 5A illustrates a side elevational view of a ring-shaped member formed from an alloy component; and

FIG. 5B illustrates an end view of the ring-shaped member of FIG. 5A.

DETAILED DESCRIPTION

Embodiments are herein described in detail in connection with the drawings of FIGS. 1-5, wherein like numbers indicate the same or corresponding elements throughout the drawings.

As illustrated in the embodiment of FIG. 1, a system 10 is shown as having multiple production stations in which to produce an alloy component 11 for use in brazing applications. In the embodiment of the system 10 generally illustrated in FIG. 1, the system 10 produces an alloy component 11 having enhanced ductility characteristics. In some embodiments, the ductility characteristics of the alloy component can be enhanced to such an extent that the alloy component 11 can be formed into the shape of rings. As shown in FIG. 1, the manufacturing system 10 can comprise multiple stages or stations. For example, the system 10 can include an extrusion station 12, drawing station 14, annealing station 16 and preform station 18, as shown in FIG. 1. At the extrusion station 12, a billet 15 composed of an alloy material enters a heating mechanism 20 and then passes through an extruder device 22, as shown in FIG. 1. The extruder device 22 extrudes the billet from a given shape and generally forms an elongated member generally in the shape of a rod or wire. The extruder device generally includes extruder dies (e.g., item 24 of FIG. 2). The extruder die is the component of the extruder device through which the billet is forced, thus producing the elongated member which ultimately forms into the alloy component. In one embodiment the extruder device can include one extruder die. In another embodiment, the extrude device can include multiple extruder dies.

Extruder dies can have any of a variety of suitable designs. One embodiment of an extruder die 24 is illustrated in FIGS. 2A and 2B. As shown in FIGS. 2A and 2B, the extruder die 24 includes a bore 26 which passes from an inlet side 28 of the extruder die 24 to an outlet side 30 of the extruder die 24. As illustrated in FIG. 2B, the diameter of the bore 26 decreases as the bore 26 passes through the extruder die 24 from the inlet side 28 to the outlet side 30. As more clearly shown in FIGS. 2A and 2B, the extruder die 24 has a ram surface 31, which includes that surface of the extruder die 24 on the inlet side 28. The number of extruder dies used for the process can vary. In one embodiment, the number of extruder dies can vary based upon the ram surface area of one extruder die versus the total surface area of the extruder die.

Once the extruded elongated member exits the extruder device 22, it can be cooled prior to entering the drawing station 14. For example, the extruded elongated member can be placed on rolls to cool prior to being sent to the drawing station 14. The drawing station 14, as generally represented in FIG. 1, is placed downstream from the extrusion station 12 such that the drawing station 14 can utilize a drawing device 32 to further manipulate the elongated member to form the alloy component 11, so that the alloy component 11 can be drawn down to a smaller, more desired shape or size. For example, the thickness of the elongated member as it exits the extruder device 22 may be larger than is ultimately desired, and the drawing device 32 can modify the thickness of the elongated member so that the proper thickness can be achieved for the alloy component 11 being formed.

One embodiment of a drawing station 14 is illustrated in FIG. 3. As shown in FIG. 3, the drawing station 14 includes a heating mechanism 34 and a drawing device 32. The heating mechanism 34 can include a tank 36 which includes a heated substance 38 (e.g., oil or lubricant), as shown in the embodiment of FIG. 3. In one embodiment, the elongated member can pass from the extrusion station 12 (see FIG. 1) to an intermediate station, for example, a payoff device (e.g., roller 33 in FIG. 3) prior to entering the drawing station 14. However, in an alternative embodiment, the elongated member can pass directly to the drawing station 14 from the extrusion station 12. As shown in FIG. 3, the elongated member leaves a roller 33 and enters the drawing station 14.

The elongated member can be heated by the heating mechanism 34 prior to entering the drawing device 32. This step softens the elongated member so that it can more easily be drawn down into a desired size or shape. The drawing device 32, as shown in FIG. 3, can include one or more drawing dies 40. One embodiment of such a drawing die is illustrated as 40 in FIG. 4). The drawing die 40 shown in FIG. 4 includes an inlet 42, an outlet 44 and a bore 50. The inlet 42 generally has a larger opening than the outlet 44, as shown in the embodiment of FIG. 4. Such an arrangement provides the capability of the drawing device 32 to reduce the diameter or thickness of the elongated member in a controlled manner as the elongated member passes through the drawing device 32. The embodiment of FIG. 4 illustrates a narrowing of the opening of the bore 50 as the bore 50 passes through the drawing die 40 from the inlet 42 to the outlet 44. The wall 46 defining the bore 50 in the drawing die 40 has various changes in its surface as the wall 46 passes from the inlet 42 to the outlet 44. These surface changes in the wall 46 can further assist in controlling the change in the diameter/thickness of the elongated member as it passes through the drawing die 40 on its way to forming the alloy component 11.

Once the elongated member is drawn down through the drawing station 14, it enters an annealing station 16 as shown in the embodiments of FIGS. 1 and 3. At the annealing station 16, the elongated member can be cooled by a cooling mechanism 48 which can set the alloy component 11. This cooling mechanism can take on various forms. In one embodiment as generally illustrated in FIG. 3, the cooling mechanism 48 can include a high pressure water sprayer 49 which dissipates the heat associated with the elongated member as it exits the drawing device 32 and allows the alloy component 11 to set into its final form. It is contemplated that the cooling mechanism can take on other forms such as a freezer or a sprayer which uses a coolant other than water to dissipate the heat associated with the wire or rod as it exits the drawing station.

As shown in the embodiment of FIG. 1, once the alloy component 11 exits the annealing station 16, the alloy component 11 (e.g., wire or rod) can be modified at a preform station 18. In one embodiment, the preform station includes a machine for mechanically manipulating the alloy component from the shape of a wire or rod into a ring-shaped member. As shown in the embodiment of FIGS. 5A and 5B, a ring-shaped member 52 can include a gap 54, wherein the gap 54 is defined by a first end 56 and a second end 58 of the alloy component. Numerous designs of such ring forming machines exist today, and it is contemplated that any such designs that are available in the marketplace can be utilized in a preform station such that the alloy component can be made into a ring-shaped member which can then be used for brazing applications associated with various applications as discussed below. In one embodiment, the ring-shaped member can have a thickness, “T”, as represented in FIG. 5A, ranging from about 0.039 inches to about 0.125 inches. In one embodiment, the ring-shaped member can have an inner diameter, “ID”, as represented in FIG. 5A, ranging from about 0.20 inches to about 10.0 inches. In another embodiment, the ring-shaped member can have an inner diameter or outer diameter that is 0.007 inches over or under the outer diameter or inner diameter, respectively, of a tube or fitting on which the ring-shaped member will be used for a brazing application. Examples of ring-shaped members having various thicknesses and inner diameters are provided below.

EXAMPLES

Example 1

Wire thickness—0.070 inches
Ring inner diameter—0.308 inches

Example 2

Wire thickness—0.070 inches
Ring inner diameter—0.366 inches

Example 3

Wire thickness—0.070 inches
Ring inner diameter—0.369 inches

The process described herein provides an alloy component with enhanced ductility characteristics, and in fact, provides an alloy component with such increased ductility that the alloy component can be formed into ring-shaped members as discussed above. The alloy component discussed herein has a liquidus temperature above about 840° F., thus making the ring-shaped members formed from the alloy component suitable for brazing applications. In fact, one embodiment of the alloy component includes the component having a brazing temperature below about 1300° F. In another embodiment, the alloy component has a brazing temperature below about 1250° F.

As noted herein, prior to the extrusion of the alloy component, the alloy material is in the form of a billet. A billet can comprise multiple forms (e.g., block or cylinder). The billet can be cast from a melting process whereby the chemical elements used to make the alloy material are added together. In one embodiment, the alloy material in its broadest form consists essentially of phosphorus, silicon, copper and at least one of tin and antimony. In another embodiment, the alloy consists essentially of from about 6.0% to about 7.0% phosphorus, from about 6.5% to about 7.0% tin and/or antimony, from about 0.005% to about 0.4% silicon and the remainder copper. In yet another embodiment, the alloy consists essentially of from about 6.5% to about 6.7% phosphorus, from about 6.65% to about 6.85% tin and/or antimony, from about 0.01% to about 0.2% silicon and the remainder copper. In another embodiment, the alloy consists essentially of about 6.6% phosphorus, about 6.75% tin and/or antimony, about 0.015% silicon and the remainder copper. It is noted, that impurities may be present by virtue of the raw materials used to manufacture the alloys or due to process conditions, and are to be distinguished from elements intentionally added to the alloy. Thus, the embodiments of the alloy materials described herein may include impurity amounts of other elements. While the alloy material can include other chemical elements, one embodiment contemplates having the alloy component formed substantially of only the elements phosphorus, tin, silicon and copper. It is noted that, in an alternative embodiment, tin could be replaced with or used in conjunction with antimony. Moreover, a benefit of adding silicon in the presence of tin is to provide a color and/or texture change of the copper base from a dull, grainy, brown finish to a very smooth finish and/or bright tin color. Silicon added to the alloy can also increase the average tensile strength of copper alloys.

In accordance with one embodiment, the ring-shaped member 52 can be placed between two metal or alloy parts and then heated such that at least a major portion of the alloy material from the ring-shaped member 52 is molten such that it flows between the two metal or alloy parts. It is contemplated that the ring-shaped member can be coated with a flux material which can be mechanically added to the ring-shaped member during manufacture or manually added subsequent to production. It will be appreciated that the flux can facilitate improved flow and bonding of the molten alloy material. Once cooled, a brazen joint is formed, wherein the material of the ring-shaped member 52 is bonded to the two metal components. When the alloy component is in the form of a ring-shaped member, it can be used in applications where the parts to be joined are substantially tubular in shape.

Other advantages to using systems, methods and alloy components as described herein can be more broadly contemplated as well. For example, the alloy component provides a low melting temperature, provides strength and gives good capillary fill on loose joints and still works effectively on tight joints.

The foregoing description of embodiments and examples has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the forms described. Numerous modifications are possible in light of the above teachings. Some of those modifications have been discussed, and others will be understood by those skilled in the art. The embodiments were chosen and described in order to best illustrate various embodiments as are suited to the particular use contemplated. It is hereby intended that the scope of the invention be defined by the claims appended hereto.

Claims

1. A method for manufacturing a brazing alloy component, the method comprising:

extruding a billet to form an elongated member, the billet comprising an alloy material consisting essentially of phosphorus, silicon, copper and at least one of tin and antimony;

drawing the elongated member through a die mechanism; and

cooling the elongated member to form an alloy component, wherein the alloy component is sufficiently ductile such that the alloy component can be formed into a ring-shaped member.

2. The method of claim 1, further comprising forming a ring-shaped member from the alloy component.

3. The method of claim 1, wherein the alloy component is in the form of a rod or a wire.

4. The method of claim 2, wherein the ring-shaped member has an inner diameter ranging from about 0.308 inches to about 0.369 inches.

5. The method of claim 1, wherein the alloy material comprises from about 6.0% to about 7.0% phosphorus, from about 6.5% to about 7.0% tin, from about 0.005% to about 0.4% silicon, and the remainder copper.

6. The method of claim 5, wherein the alloy material comprises from about 6.5% to about 6.7% phosphorus, from about 6.65% to about 6.85% tin, from about 0.01% to about 0.2% silicon, and the remainder copper.

7. The method of claim 6, wherein the alloy material comprises about 6.6% phosphorus, about 6.75% tin, about 0.015% silicon, and the remainder copper.

8. The method of claim 1, wherein the step of cooling the elongated member comprises contacting the elongated member with water.

9. The method of claim 8, wherein the water contacts the elongated member under a pressurized state.

10. The method of claim 1, further comprising dividing the alloy component into a plurality of sections.

11. An alloy component sufficiently ductile to form a ring-shaped member, wherein the alloy component is manufactured from the method of claim 1.

12. The alloy component of claim 11 comprising a ring-shaped member.

13. A method of manufacturing a brazing alloy component, the method comprising:

means for extruding a billet to form an elongated member, wherein the billet comprises an alloy material consisting essentially of phosphorus, silicon, copper and at least one of tin and antimony;

means for drawing the elongated member through a die;

means for cooling the elongated member to form an alloy component; and

means for forming a ring-shaped member from the alloy component.

14. A system of manufacturing a brazing alloy component, the system comprising:

an extrusion device configured to extrude a billet to form an elongated member, wherein the billet comprises an alloy material consisting essentially of phosphorus, silicon, copper and at least one of tin and antimony, and wherein the elongated member has a predetermined thickness;

a heating mechanism configured to heat the elongated member exiting the extrusion device;

a drawing device configured to receive the elongated member from the heating mechanism and modify the elongated member, wherein the modified elongated member has a smaller thickness than the predetermined thickness; and

a cooling mechanism configured to cool the elongated member having exited the drawing device to form an alloy component.

15. The system of claim 14, wherein the system further comprises a preform machine configured to form the alloy component into a ring-shaped member.

16. The system of claim 14, wherein the alloy material comprises from about 6.0% to about 7.0% phosphorus, from about 6.5% to about 7.0% tin, from about 0.005% to about 0.4% silicon, and the remainder copper.

17. The system of claim 14, wherein the heating mechanism comprises heating oil.

18. The system of claim 14, wherein the extrusion device includes at least one extruder die.

19. The system of claim 15, wherein the ring-shaped member has an inner diameter ranging from about 0.20 inches to about 10.0 inches.

20. The system of claim 15, wherein the ring-shaped member has a thickness ranging from about 0.039 inches to about 0.125 inches.