A wire preform suitable for use in brazing components to one another. The preform is made from a length of wire having a core of flux material, and a longitudinal seam or gap that extends over the length of the wire. The seam is formed so that when heated, the flux material flows from the core and out of the seam. The length of wire is in the form of a loop having a certain circumference so that when the preform is heated, the flux material disperses uniformly from the circumference of the preform for evenly treating the surface of a component on which the preform is placed. The length of wire may include a silver alloy.
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0. 9. A preform comprising:
a length of metal having a core of a flux material for joining components to one another, and a longitudinal gap extending over the length of the metal;
wherein the gap is formed to allow the flux material to evenly flow from the core and out of the gap of the metal; and
wherein the length of metal is formed into a ring, and the gap of the metal is defined by an inner circumference portion of the ring.
0. 13. A material for joining components to one another comprising:
a length of metal formed into a U-shaped channel by a die;
a core of flux in the U-shaped channel created by passing the channel through a trough by pulling the length of metal in a direction away from a dispensing apparatus;
at least one wall of metal around the core; and
a path for the flux from the core to aid in release of the flux;
wherein the metal then passes through another die and is formed to its final size diameter, while maintaining the path;
wherein when the metal is heated, the flux is dispersed from the core to evenly treat a component surface;
wherein the flux has a melting temperature and the length of metal has a melting temperature at least above the melting temperature of the flux.
0. 30. A material for joining components to one another comprising:
a length of metal formed into a U-shaped channel by a die;
a core of flux in the U-shaped channel created by passing the channel through a trough by pulling the length of metal in a direction away from a dispensing apparatus;
at least one wall of metal around the core; and
a path for the flux from the core to aid in release of the flux;
wherein the metal then passes through another die and is formed to its final size and shape, while maintaining the path;
wherein when the metal is heated, the flux is dispersed from the core to evenly treat a component surface;
wherein the flux has a melting temperature and the length of metal has a melting temperature at least above the melting temperature of the flux.
0. 1. A wire preform suitable for use in brazing components to one another, comprising:
a length of wire having a core of a flux material, and a longitudinal seam or gap extending over the length of the wire wherein the seam is formed so that when heated, the flux material flows from the core and out of the seam of the wire; and
the length of wire is in the form of a loop having a certain circumference so that when the preform is heated, flux material is dispersed uniformly from the circumference of the preform for evenly treating a component surface on which the preform is disposed.
0. 2. A wire preform according to
0. 3. A wire preform according to
0. 4. A wire preform according to
0. 5. A wire preform according to
0. 6. A wire preform according to
0. 7. A wire preform according to
0. 8. A wire preform according to
0. 10. The preform of claim 9, wherein the preform may be at least one of: an oval, a square, a multi-form helical loop; a braze ring; a helical shape having a circular cross-section; and a wire having a diameter between about 0.031 and about 0.125 inches.
0. 11. The preform of claim 9, wherein when the preform reaches a temperature between approximately 500 and approximately 1100 degrees F., flux is dispersed from the gap uniformly along a circumference of the preform.
0. 12. The preform of claim 9, wherein the flux has a melting temperature of approximately 500 and approximately 1100 degrees F., and wherein the metal has a melting temperature at least above the melting temperature of the flux.
0. 14. The material of claim 13, wherein the material is then packaged in spools.
0. 15. The material of claim 13, wherein the metal is an alloy of at least one of the following: aluminum-silicon; zinc-aluminum; copper zinc; silver-copper-zinc; silver-copper-zinc-tin; silver copper-zinc-tin-nickel; silver-copper-zinc-nickel; silver-copper-tin; silver-copper-zinc-manganese-nickel; silver-copper-zinc-cadmium; and silver-copper-zinc-cadmium.
0. 16. The material of claim 13, wherein the length of metal is a narrow elongate strip coiled onto a spool to facilitate feeding of the length of metal during a manufacturing process.
0. 17. The material of claim 13, wherein the material is formed into a brazing wire having a size and a cross section of a desired shape and adopting a configuration that is complementary to various angles and sizes of surfaces to be brazed.
0. 18. The material of claim 13, wherein the core has a cross-section in the shape of an oval.
0. 19. The material of claim 13, wherein the core has a cross-section defined by at least first and second walls that are substantially perpendicular to one another.
0. 20. The material of claim 19 wherein the core has a cross-section in the shape of a square.
0. 21. The material of claim 13 is in the shape of a helical loop.
0. 22. The material of claim 13 is formed into a braze ring preform.
0. 23. The material of claim 13 wherein the core has a circular cross-section.
0. 24. The material of claim 13 wherein the length of metal wrapped around the core has a diameter between about 0.031 and about 0.125 inches.
0. 25. The material of claim 13 wherein a butt seam is formed between opposed ends of the length of metal, and wherein the path is defined at the butt seam.
0. 26. The material of claim 13 arranged into a preform having an inner perimeter surface and an outer perimeter surface, wherein the butt seam is formed along the inner perimeter surface.
0. 27. The material of claim 13 wherein the path is formed by overlapping portions of the metal.
0. 28. The material of claim 13, wherein the metal's final size diameter includes a measurement of cross sectional width for any shape.
0. 29. The material of claim 13, wherein the dies may include any manufacturing die, including roll forming dies.
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The wire then passes through a fourth die which forces an edge portion of the seam inward, e.g., about 0.005″ to 0.010″. This portion is maintained to about 45 degrees or less of the circumference of the wire, and leaves a gap between the opposed edge portions of strip. The inner edge portion extends toward the center of the cored wire, and the space between the edge portions contains flux. See , see
The wire then passes through a fifth die where the wire is formed to its final size diameter, while maintaining the seam as described above. The flux cored wire is then packaged on spools and other suitable packaging systems.
The metal alloy strip can be any of the following alloys, among others: aluminum-silicone; zinc-aluminum; copper zinc; silver-copper-zinc; silver-copper-zinc-tin; silver copper-zinc-tin-nickel; silver-copper-zinc-nickel; silver-copper-tin; silver-copper-zinc-manganese-nickel; silver-copper-zinc-cadmium; and silver-copper-zinc-cadmium and nickel.
The flux-cored brazing wire formed as described above can subsequently be formed to into brazing preforms having any desired shape, such as a circle or oval. The preforms can then be placed between or adjacent to faying surfaces of components to be joined. The preforms and the faying surfaces are then heated to a suitable brazing temperature sufficient to melt the flux and the brazing alloy and, thus, bond the faying surfaces. The components are then cooled to solidify the brazing alloy and to secure the bond between the faying surfaces.
As shown in cross section in
The metal alloy strip 12 may be formed or bowed into a brazing wire having a cross section of any desired shape and size. For example, the strip 12 may be rolled about its longitudinal axis in a substantially circular manner to form the wire 10 in
As mentioned, the seamed, flux cored brazing wire 10 may be manufactured by other techniques that are known in the art. For example, roll forming technology, alone and in combination with dies, can be employed to produce a cored wire. The cored wires may also be produced with a gap to allow flux dispersion from the seam.
Cored wire with a butt seam may also be produced, and due to other factors (like an oval, square or other shape of preforms made from the wire) the flux will be allowed to escape from the seam during brazing.
When the flux-cored preform 44 reaches a temperature between 500 and 1100° F., flux can be seen dispersing from the wire seam uniformly along the full circumference of the preform 44 as shown in
While there have been described what are at present considered to be the preferred embodiments of this invention, it will be obvious to those skilled in the art that various changes and modifications may be made thin without departing from the true spirit and scope of the invention defined by the following claims.
Fuerstenau, Charles E., Belohlav, Alan
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