# US 6,720,086 B1 · Liquid interface diffusion bonding of nickel-based superalloys > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 6,720,086 B1 - Document ID: US6720086B1 - Status: Granted - Kind: B1 - Application number: 10/010,553 - Filed: 2001-11-02 - Granted: 2004-04-13 - Earliest claimed: 2001-11-02 - Assignees: Rohr, Inc. - Inventors: Andrew J. Strutt - Web page: https://patentgrep.com/patent/US6720086B1 ## CPC - B32B 15/01: all layers being exclusively metallic {(making layered metal workpieces by pressure cladding B23K20/22; making coatings with a metallic material characterised by its composition C23C30/00)} - B23K 35/004: {at least one of the workpieces being of a metal of the iron group} - B23K 20/16: with interposition of special material to facilitate connection of the parts, e.g. material for absorbing or producing gas - B23K 35/3033: {Ni as the principal constituent} - B23K 2101/02: Honeycomb structures - Y10T 428/1234: Honeycomb, or with grain orientation or elongated elements in defined angular relationship in respective components [e.g., parallel, inter- secting, etc.] - Y10T 428/12806: Refractory [Group IVB, VB, or VIB] metal-base component - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - B23K: SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract A liquid interface diffusion bonded composition comprises a metal honeycomb core such as a nickel-alloy honeycomb core and a nickel-alloy facing sheet bonded thereto. The composition and method of this invention are useful in applications where high strength, heat resistant materials are required, such as in aircraft and aerospace-related structures. The composition is prepared by a method comprising: (a) providing a nickel-alloy honeycomb core having a mating surface and a nickel-alloy facing sheet having a mating surface; (b) placing together the honeycomb core mating surface and the facing sheet mating surface, and providing therebetween a metal foil comprising nickel, zirconium, and at least one additional metal selected from the group consisting of titanium, niobium, and chromium; (c) subjecting the mating surfaces and metal foil therebetween to sufficient positive pressure to maintain position and alignment for joining; and (d) heating the mating surfaces and metal foil therebetween in a protective atmosphere for at least 2 hours to a temperature sufficient to cause melting between the metal foil and mating surfaces of the facing sheet and honeycomb core. ## Claims ### Claim 1 A liquid interface diffusion bonded composition prepared by a method comprising: (a) providing a nickel-alloy honeycomb core having a mating surface and a nickel-alloy facing sheet having a mating surface; (b) placing together the honeycomb core mating surface and the facing sheet mating surface, and providing therebetween a metal foil comprising nickel, zirconium, and at least one additional metal selected from the group consisting of titanium and niobium; (c) subjecting the mating surfaces and metal foil therebetween to sufficient positive pressure to maintain position and alignment for joining; and (d) heating the mating surfaces and metal foil therebetween in a protective atmosphere to a temperature in the range of about 1840 to about 2000 degrees F. for at least 2 hours to cause melting between the metal foil and mating surfaces of the facing sheet and honeycomb core. ### Claim 2 (depends on 1) The composition of claim 1, in which the metal foil comprises about 10 to about 14 wt. % zirconium and about 8 to about 12 wt. % titanium, the remainder being nickel. ### Claim 3 (depends on 1) The composition of claim 1, in which the metal foil comprises about 10 to about 14 wt. % zirconium and about 20 to about 28 wt. % niobium, the remainder being nickel. ### Claim 4 (depends on 1) The composition of claim 1, in which the metal foil does not comprise copper and does not comprise boron and does not comprise silicon. ### Claim 5 (depends on 1) The composition of claim 1, in which the mating surfaces and metal foil therebetween are heated to a temperature of about 1900 degrees F. for about 2 hours. ### Claim 6 (depends on 5) The composition of claim 5, in which the mating surfaces and metal foil therebetween are heated to a temperature of about 1900 degrees F. for about 2 hours and thereafter cooled to room temperature. ### Claim 7 A liquid interface diffusion bonded composition prepared by a method comprising: (a) providing a nickel-alloy honeycomb core having a mating surface and a nickel-alloy facing sheet having a mating surface; (b) placing together the honeycomb core mating surface and the facing sheet mating surface, and providing therebetween a metal foil comprising nickel, zirconium, and chromium, wherein the foil does not comprise boron; (c) subjecting the mating surfaces and metal foil therebetween to sufficient positive pressure to maintain position and alignment for joining; and (d) heating the mating surfaces and metal foil therebetween in a protective atmosphere to a temperature in the range of about 2500 to about 2700 degrees F. for at least 2 hours to cause melting between the metal foil and mating surfaces of the facing sheet and honeycomb core. ### Claim 8 (depends on 7) The composition of claim 7, in which the metal foil has a thickness of about 0.0008-0.0012 inches. ### Claim 9 (depends on 8) The composition of claim 8, in which the metal foil has a thickness of about 0.001 inches. ### Claim 10 (depends on 5, 7) The composition of claim 7 or 5, in which the metal foil is formed by a rapid solidification process or a melt spinning process. ### Claim 11 A liquid interface diffusion bonded composition prepared by a method comprising: (a) providing a nickel-alloy honeycomb core having a mating surface and a nickel-alloy facing sheet having a mating surface; (b) placing together the honeycomb core mating surface and the facing sheet mating surface, and providing therebetween a metal foil comprising about 10 to about 14 wt. % zirconium and about 45 to about 50 wt. % chromium, the remainder being nickel; (c) subjecting the mating surfaces and metal foil therebetween to sufficient positive pressure to maintain position and alignment for joining; and (d) heating the mating surfaces and metal foil therebetween in a protective atmosphere to a temperature in the range of about 2500 to about 2700 degrees F. for at least 2 hours to cause melting between the metal foil and mating surfaces of the facing sheet and honeycomb core. ### Claim 12 A liquid interface diffusion bonded composition prepared by a method comprising: (a) providing a nickel-alloy honeycomb core having a mating surface and a nickel-alloy facing sheet having a mating surface; (b) placing together the honeycomb core mating surface and the facing sheet mating surface, and providing therebetween a metal foil comprising nickel, zirconium, and chromium, and the metal foil does not comprise copper and does not comprise boron and does not comprise silicon; (c) subjecting the mating surfaces and metal foil therebetween to sufficient positive pressure to maintain position and alignment for joining; and (d) heating the mating surfaces and metal foil therebetween in a protective atmosphere to a temperature in the range of about 2500 to about 2700 degrees F. for at least 2 hours to cause melting between the metal foil and mating surfaces of the facing sheet and honeycomb core.