Product and method of brazing using kinetic sprayed coatings
AssigneeDelphi Technologies, Inc.
InventorsBryan A. Gillispie, Zhibo Zhao, John Robert Smith, Thomas Hubert Van Steenkiste, Alaa A. Elmoursi, Yang Luo, Hartley F. Hutchins
Life of this patent
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Abstract
The present invention is directed to a process for preparing aluminum and aluminum alloy surfaces in heat exchangers for brazing by depositing thereon a kinetic sprayed brazing composition. The process simultaneously deposits monolith or composite coatings that can include all braze materials and corrosion protection materials used in the brazing of aluminum fins to plates and tubes in a single stage.
Claims25
A process for brazing an aluminum surface comprising:
- a. selecting a solid phase monolith or composite brazing composition comprising particles of corrosion protector for aluminum, filler material for brazing, brazing flux, or mixtures thereof;
- b. introducing said brazing composition into a focused gas stream;
- c. entraining said brazing composition in said gas stream;
- d. accelerating said brazing composition toward said aluminum surface;
- e. impacting continuously said brazing composition onto said aluminum surface to form a brazing composition, said brazing composition remaining in its original solid phase from said selection of said brazing composition to form said brazing composition on said aluminum surface.
A brazable aluminum substrate comprising an aluminum surface and a kinetically impinged coating bonded thereon, wherein said coating is a solid phase monolith or composite comprising corrosion protector for aluminum, filler material for brazing, brazing flux, or mixtures thereof, having at least one layer kinetically bonded to said aluminum surface that is substantially free of oxidation within said layer, and which substantially retains the same physical properties and solid phase as the original pre-coating composition.
A method of brazing comprising:
- providing a metal surface;
- providing a brazing composition;
- kinetically spraying said brazing composition onto said metal surface.
A method of fluxless, cladless brazing comprising:
- providing a metal surface;
- providing a brazing coating;
- cleaning and deoxidizing said metal surface in a single kinetic spraying step that sprays said coating onto said metal surfaces.
A process for brazing a surface comprising:
- a. selecting a solid phase monolith or composite brazing composition comprising particles of corrosion protector, filler material for brazing, brazing flux, or mixtures thereof;
- b. introducing said brazing composition into a focused gas stream;
- c. entraining said brazing composition in said gas stream;
- d. accelerating said brazing composition toward said surface;
- e. impacting continuously said brazing composition onto said surface to form a brazing composition, said brazing composition remaining in its original solid phase from said selection of said brazing composition to form said brazing composition on said surface.
A brazable substrate comprising a metal surface and a kinetically impinged coating bonded thereon, wherein said coating is a solid phase monolith or composite comprising corrosion protector for said metal, filler material for brazing, brazing flux, or mixtures thereof, having at least one layer kinetically bonded to said metal surface that is substantially free of oxidation within said layer, and which substantially retains the same physical properties and solid phase as the original pre-coating composition.
A process for brazing a metal surface comprising:
- a. selecting a solid phase monolith or composite brazing composition comprising particles of corrosion protector for metal, filler material for brazing, brazing flux, or mixtures thereof;
- b. introducing said brazing composition into a focused gas stream pre-heated to a temperature sufficient low to maintain said particles in their original solid phase;
- c. entraining said brazing composition in said gas stream;
- d. accelerating said brazing composition toward said metal surface;
- e. impacting continuously said brazing composition onto said metal surface to form a brazing composition, said brazing composition remaining in its original solid phase from said selection of said brazing composition to form said brazing composition on said metal surface.
A process for brazing a metal surface comprising:
- a. selecting a solid phase monolith or composite brazing composition comprising particles of corrosion protector for metal, filler material for brazing, brazing flux, or mixtures thereof;
- b. introducing said brazing composition into a focused gas stream;
- c. entraining said brazing composition in said gas stream;
- d. accelerating said brazing composition toward said metal surface at a velocity sufficient to fracture a surface oxide layer and form a mechanical bond between said particles and said metal surface;
- e. impacting continuously said brazing composition onto said metal surface to form a brazing composition, said brazing composition remaining in its original solid phase from said selection of said brazing composition to form said brazing composition on said metal surface.
Dependencies are inferred from the claim text.