DE102007033813A1 - Firmly bonded joint of two aluminum components, which are connected together in joining regions and have joining means corresponding in the joining regions and formed as groove and/or spring, useful in heat exchanger for vehicles e.g. cars - Google Patents

Abstract

The firmly bonded joint of two aluminum components (10, 12), which are connected together in respective joining regions (16, 18) and have joining means corresponding in the joining regions and formed as groove (32) and/or spring running in the joining regions, is claimed. The aluminum components consist of same aluminum-pressure die cast alloys in the joining region with an iron content of less than 1.0-1.5 wt.%. The aluminum-pressure die cast alloys are joined with one another by a hard solder joint. The joint is produced using a non-corrosive fluxing agent or corrosive fluxing agent. The firmly bonded joint of two aluminum components (10, 12), which are connected together in respective joining regions (16, 18) and have joining means corresponding in the joining regions and formed as groove (32) and/or spring running in the joining regions, is claimed. The aluminum components consist of same aluminum-pressure die cast alloys in the joining region with an iron content of less than 1.0-1.5 wt.%. The aluminum-pressure die cast alloys are joined with one another by a hard solder joint. The joint is produced using a non-corrosive fluxing agent or corrosive fluxing agent and using a filler material and/or a plumbline on aluminum-basis. The melting region of the filler material and/or the plumbline lies close beneath the solidus line of the aluminum-pressure die cast alloys of the aluminum components. The aluminum components are soldered with one another in the joining region in the cast condition, and are connected with one another by induction soldering. The filler material and/or the plumbline are brought between the groove and the spring. Independent claims are included for: (1) a method for firmly bonded joining of two aluminum components; and (2) heat exchanger for vehicles.

Description

The The present invention relates to a cohesive joining compound of at least two aluminum components in the preamble of the claim 1 specified type. Furthermore, the invention relates to a method for cohesive joining of two aluminum components The type specified in the preamble of patent claim 14. Finally the invention a heat exchanger, in particular for vehicles, with at least two aluminum components according to the Preamble of claim 25.

Cohesive joining compounds are used in a wide range of applications. One field of application is soldering, in particular brazing, which already for example from the EP 1 439 367 A1 to be known as known. There, a heat exchanger in the form of a cooler / heat exchanger is created in that a plurality of components such as two manifolds, a plurality of flat tubes, and refrigerant flanges are first assembled with the aid of auxiliary or clamping means and then soldered.

It However, it is apparent that this particular for mating and joining a variety of steps required is to create the heat exchanger.

task The present invention is a cohesive Joining compound and a method for cohesive To create joining of at least two aluminum components, with which, in a broad field of application, a particularly simple, Process-reliable and fast connection of the two aluminum components to realize a total component.

These The object is achieved by a cohesive Joining compound and a method for cohesive Joining of at least two aluminum components with the features of claims 1 and 14 solved. Furthermore This task is performed by a heat exchanger solved with the features of claim 25.

at the cohesive joining compound according to the invention becomes one over the prior art completely new way began by two at least in the respective joining area aluminum components made of a respective die-cast aluminum alloy are used, which by a solder joint, in particular connected by a braze joint.

These measures according to the invention open up completely new possibilities, which are reflected, for example, in a simple, process-reliable and cost-effective production of corresponding overall components. Thus, it can initially be seen that the respective aluminum components involved in the joining connection can be made extremely simple since they consist of a respective aluminum die-cast alloy. Namely, such components can be manufactured in large numbers even with complex geometry as one-piece components, so that this can be realized by a simple production of the aluminum components involved in the cohesive Fügverbindung first. In contrast, namely, for example, heat exchangers, such as these from the EP 1 439 367 A1 are known to be composed of a much larger number of components. In particular, the advancing manufacturing technologies in aluminum die-casting alloys, however, make it possible to cast a large number of the previous individual components in one piece or summarize.

Of Furthermore, it has been found in the present invention that which expresses at least two of aluminum die-cast aluminum existing aluminum components reliable and process-safe by soldering, in particular by brazing, joined together, respectively can be connected. In this case, cohesive ones have Solder connections give, which also considerable loads for example when used with heat exchangers withstand the best. Here are the solder joints in particular the fact that this manifests itself in the production easy to handle and material-related tolerances between balance the two aluminum components to the best.

All in all is thus apparent that in this case a novel cohesive Fügverbindung is created, which on the one hand the advantages die casting of corresponding aluminum alloys with the advantages of joining technology of soldering to connect is able. This results in the desired, easy and reliable to produce and inexpensive Total components, for example, for heat exchangers.

When Within the scope of the invention, it is to be considered that the aluminum components in each case at least in Fügbereich - ie in each case to the Fügverbindung or solder joint adjacent component area - made of die-cast aluminum. This means that, for example, hybrid components with recessed or cast-in other components accordingly can be used, provided that at least in each case Joining area of its respective die-cast aluminum alloy consist.

In Another embodiment of the invention, it has it In addition, shown as advantageous when the aluminum components at least in the respective joining area from a respective die-cast aluminum alloy consist with an iron content of less than 1.0 wt .-% Fe. hereby can easily be a Fügverbindung create with the help of a non-corrosive flux. Such a non-corrosive flux has the special Advantage that this is not necessarily created by the Joining must be removed.

Should joined in a further embodiment of the invention aluminum components which, at least in the respective joining area, consists of a respective die-cast aluminum alloy with an iron content of 1.0 to 2.0 wt .-% Fe and in particular with an iron content of 1.0 to 1.5 wt .-% Fe, it can, in particular with the aid of a corrosive flux can be achieved. This leaves an even wider field of application also of aluminum die-cast alloys above reach an iron content of 1.0 wt .-% Fe, in which case the corrosive Flux preferred from the created joining compound for example with water or another liquid washed off or removed chemically or mechanically.

When In addition, it has been shown to be advantageous, the Fügverbindung with the aid of an additional material or a solder based on aluminum to accomplish. These filler metals or solders are preferred no or only a small amount of heavy metals - as well preferably an aluminum content of at least 70 wt .-% Al - on. such Add-on materials or solders based on aluminum have the special Advantage that their mechanical properties of those used Aluminum die-cast alloys come close. Thus, in total an extremely resilient cohesive Fügverbindung be created.

There when soldering the base material will not be melted may, on the other hand, however, a particularly good cohesive Fügverbindung is to be produced, it has in further Embodiment of the invention shown as advantageous when the melting range of filler metal or solder near below the solidus line the respective aluminum die-casting alloys of the aluminum components lies. In this case, for example, a melting range is selected, which is about 0 to 150 ° C below the solidus line of respective aluminum die-casting alloy of the aluminum components. With In other words, a temperature would be right in the range the solidus line conceivable.

In Another embodiment of the invention has been found to be advantageous if the two aluminum components at least in the respective joining area are soldered together in the cast state. This can a particularly economical production of cohesive Fügverbindung be guaranteed. Because the aluminum components at least in their respective joining area in the cast state Of course, it would also be conceivable that partially heat-treat both aluminum components in other component areas, for example, other material properties in terms of hardness or to achieve ductility.

When Furthermore, it has proven advantageous if the aluminum components at least in the respective joining area from the same aluminum diecasting alloy consist. This has the advantage of a particularly uniform transition in the area of cohesive joining compound. Moreover, it is easily possible to use a suitable filler material or a suitable solder.

After all It has proved to be advantageous if the aluminum components in the respective joining area corresponding connection means have, which cooperate with each other in the manner of a positive connection. Thus, a centering of the cohesive Fügverbindung achieved, resulting in a particularly process-reliable production of the entire component contributes.

The Connecting means can in a further embodiment of the Invention than in the respective joining area - for example in the respective joining flange - running groove or Spring be formed, so that a circumferential centering the two aluminum components can be realized. In the area the connecting means or the respective tongue and groove can about it In addition, the additional material or the solder positioned in a simple way become. This can be done, for example, that the filler material is positioned within the groove.

The above in connection with the cohesive Fügverbindung described described advantages apply in the same way for the inventive method for cohesive joining of two aluminum components according to claim 14. Likewise, the advantages described as advantages of the heat exchanger according to claim 25 to consider.

As included in the scope of the invention, it is furthermore to be considered that, in addition to the heat exchangers, it is also possible to use other components with such a cohesive joining connection, which are used, for example, in vehicles such as motor vehicles, motorhomes or trailers. The application area However, this cohesive Fügverbindung is not limited to vehicles. In addition, it would also be conceivable, for example, to use such cohesive joining compounds or such methods for joining aluminum components in heating or heating technology.

Further Advantages, features and details of the invention will become apparent the following description of a preferred embodiment as well as from the drawings; these show in:

1 a schematic and perspective exploded view of two formed as part shells aluminum components of a heat exchanger or heat exchanger, which are connected via respective, designed as Fügflansche joining areas by a cohesive Fügverbindung in the form of a braze joint together, the Fügflansche with connecting means in the form of a circumferential groove or a circumferential spring are provided, through which a centering or positioning of the two aluminum components takes place relative to each other;

2 a schematic sectional view through the joining areas or

Fügflansche the two, designed as partial shells aluminum components the soldering, wherein the groove within the one Fügflansches and the spring within the other Fügflansches each other Corresponded are formed, and wherein in the groove a additional material is inserted, which in the subsequent soldering connects the two aluminum components together; and in

3 a flowchart of a process flow for the production of cohesive joining compound, which comprises a method for producing the two of aluminum die-cast aluminum existing aluminum components and a method for joining the two aluminum components by a solder joint.

In 1 are in a schematic and perspective exploded view of two formed as part shells aluminum components 10 . 12 a heat exchanger 14 shown. The two aluminum components 10 . 12 in the present case consist of a respective aluminum die cast alloy, for example of the type AlSi9 CU3 (modified). In the present embodiment, the two aluminum components 10 . 12 Consequently, from an at least largely identical die-cast aluminum alloy. As included in the scope of the invention, however, it should be considered that the two aluminum components 10 . 12 could also consist of different die-cast aluminum alloys.

It should also be noted that instead of the aluminum components made entirely of die-cast aluminum alloy here 10 . 12 Hybrid components could be used, these at least in a respective, designed as a joining flange joining area 16 . 18 Made of die-cast aluminum. In other words, it would therefore also be conceivable to use hybrid components in which components of other material are cast or fastened accordingly.

Furthermore, it is off 1 recognizable that the two formed as Fügflansche joining areas 16 . 18 are adapted to each other in their contour, so that the two partial shells or aluminum components 10 . 12 can be connected to each other.

Moreover, it is off 1 recognizable that the two aluminum components 10 . 12 at their respective broadsides with ribs 20 . 22 are provided, which serve the heat exchange. Because the two aluminum components 10 . 12 in the present case consist of a respective die-cast aluminum alloy, the ribs 20 . 22 be integrally formed in a simple manner. Of course, other designs would be conceivable here.

On the ribs 20 opposite side are a plurality of vanes 24 as well as a wall 26 in one piece to the corresponding aluminum component 10 formed. This is also possible in a simple manner, since the aluminum component 10 consists of the corresponding die-cast aluminum alloy. Finally, a plurality of terminals 28 . 30 to the respective aluminum component 10 . 12 formed over to achieve an inlet and outlet of the respective heat exchanging medium.

The heat exchanger 14 is used in the present case in a vehicle, in particular a motorhome or caravan. Of course, the application described below is not limited to vehicles. Rather, it would also be possible to use such heat exchangers in heating and heating technology.

2 shows in a schematic sectional view fragmentary the two joining flanges or joining regions 16 . 18 , It is in synopsis with 1 in particular recognizable that the one Fügflansch or Fügbereich 16 a connecting means in the form of a groove 32 which, in the present case, has at least approximately the complete joining area 16 circulates. With the groove 32 corresponds to a spring 34 , which depends on the corresponding joining flange or joining area 18 raised in the direction of the groove 32 or the joining area 18 projects. The feather 34 is - according to the groove 32 - also over the at least approximately complete joining area 18 formed circumferentially. As is included in the scope of the invention, it should be considered that the groove 32 or - adapted to it - the spring 34 only in subareas of the respective joining areas 16 . 18 could be provided. Likewise, it would also be possible to choose other connecting means, such as with holes or blind holes corresponding pin.

In particular from 2 is recognizable that the groove 32 and the spring 34 are adapted to each other in their cross-section. As a result, a centering or positioning of the two aluminum components 10 . 12 achieved in the manner described in more detail below.

The two aluminum components 10 . 12 Be aware of their joining areas 16 . 18 by a solder joint, in this case by a brazing joint, joined together or connected. The Fügverbindung takes place with the help of a filler material 36 on aluminum basis. It is clear that other filler metals or solders can be used.

Out 3 it can be seen that the filler material 36 doing so before soldering in the groove 32 inserted or introduced. As a result, it also becomes clear that 2 the two joining areas 16 . 18 before soldering shows. Here is the groove 32 However, designed so deep that, despite the inserted filler material 36 a pre-centering - within certain limits - of the spring 34 results. In other words, the cross section of the groove 32 or the spring 34 chosen correspondingly larger than that of the filler material. This ensures that the spring 34 at least partially into the groove 32 dips.

The additional material 36 In the present case, it is chosen such that its melting range is close to below the solidus line of the respective aluminum die cast alloys of the two aluminum components 10 . 12 lies. In this context, a temperature range from 0 to 150 ° C. below the solidus line of the respective aluminum diecasting alloys is to be understood as meaning in particular. This ensures that on the one hand a particularly good Fügverbindung is achieved, and on the other hand, a melting of the base material of the aluminum components 10 . 12 effectively prevented.

The Fügverbindung further takes place with the aid of a flux. This may preferably not be corrosive, namely when the aluminum components 10 . 12 at least in the respective joining area 16 . 18 consist of a respective die-cast aluminum alloy with an iron content of less than 1.0 wt .-% Fe. On the other hand, if an aluminum die casting alloy having an iron content of 1.0 to 2.0% by weight of Fe, and more preferably having an iron content of 1.0 to 1.5% by weight of Fe is used, for example, a corrosive flux is used , By appropriate choice of the flux thus dissolving or reducing the oxide skin is achieved in a preferred manner. Likewise, it would of course also be conceivable to tear or remove this oxide skin mechanically.

Based on the flowchart according to 3 Now is the process of manufacturing the heat exchanger 14 be explained in more detail. The process sequence differs in two main sub-processes, namely the casting or preparation of the two aluminum components 10 . 12 as well as the process for material-liquid joining of the two aluminum components 10 . 12 ,

Now to the process of casting the two aluminum components 10 . 12 The aluminum die-cast alloy is first melted in accordance with process step G1, the melt is degassed in accordance with process step G2, and both aluminum components are removed in a process step G3 10 . 12 poured accordingly. In process step G3 of the casting, a stamping or removal of the pouring residue or casting residue and, if appropriate, straightening of the aluminum components are thereby completed 10 . 12 at. In the present embodiment, the aluminum components 10 . 12 consequently soldered in their casting condition. However, it is to be considered within the scope of the invention that, if appropriate, a heat treatment can be carried out before soldering. In particular, it would also be conceivable, the two aluminum components 10 . 12 only to heat treat partially, for example, if in some subsections another ductility or hardness of the respective component to be set.

The process of joining the two aluminum components 10 . 12 to the cohesive joining compound essentially comprises the method steps L1 and L2. In method step L1, in particular, the joining areas 16 . 18 washed accordingly or freed from fats or other residues. In the process step 12 an automated brazing, in this case by induction soldering by means of solder tongs. As included in the scope of the invention, however, it should be considered that of course all other common soldering methods can be used for brazing. In particular, hot air soldering, laser soldering or resistance soldering is also conceivable. In the present embodiment, this is done with the aid of the above-described filler material 36 and the corresponding non-corrosive or corrosive flux. Of course, it would also be possible without flux, for example under inert gas or Va to be soldered.

During the soldering process, the filler material 36 doing so at the joining areas 16 . 18 distributed, that - according to 2 - At least approximately a positive connection between the groove 32 and the spring 34 results.

In the process step 12 In addition, a leak test of the heat exchanger 14 be assigned. Also, subsequent brazing may be followed by processing, such as removal of the flux.

Finally, the heat exchanger 14 packed in a subsequent method step V.

It It is clear that the present process steps also split differently or that additional process steps be introduced. Likewise, certain Procedural steps are omitted.

As included in the scope of the invention, it should be considered that the cohesive joining compound provided here by soldering, in particular by brazing 14 , at least two aluminum components 10 . 12 can also be used in other technical fields.

QUOTES INCLUDE IN THE DESCRIPTION

This list The documents listed by the applicant have been automated generated and is solely for better information recorded by the reader. The list is not part of the German Patent or utility model application. The DPMA takes over no liability for any errors or omissions.

Cited patent literature

• - EP 1439367 A1 [0002, 0007]

Claims (25)

Cohesive joining of two aluminum components ( 10 . 12 ), which in a respective joining area ( 16 . 18 ), characterized in that the aluminum components ( 10 . 12 ) at least in the respective joining area ( 16 . 18 ) consist of a respective die-cast aluminum alloy, which are joined together by a solder joint, in particular by a braze joint. Cohesive joining connection according to claim 1, characterized in that the aluminum components ( 10 . 12 ) at least in the respective joining area ( 16 . 18 ) consist of a respective aluminum die casting alloy with an iron content of less than 1.0 wt .-% Fe. Cohesive joining compound according to Claim 2, characterized in that the Fügverbindung under With the help of a non-corrosive flux is created. Cohesive joining connection according to claim 1, characterized in that the aluminum components ( 10 . 12 ) at least in the respective joining area ( 16 . 18 ) consist of a respective aluminum die cast alloy having an iron content of 1.0 to 2.0 wt .-% Fe, and in particular having an iron content of 1.0 to 1.5 wt .-% Fe. Cohesive joining compound according to Claim 4, characterized in that the Fügverbindung under With the help of a corrosive flux is created. Cohesive joining compound according to one of claims 1 to 5, characterized in that the Fügverbindung with the aid of a filler material ( 36 ) or an aluminum-based solder. Cohesive joining compound according to claim 6, characterized in that the melting range of the filler material ( 36 ) or the solder near below the solidus line of the respective aluminum die-casting alloy of the aluminum components ( 10 . 12 ) lies. Cohesive joining connection according to one of claims 1 to 7, characterized in that the two aluminum components ( 10 . 12 ) at least in the respective joining area ( 16 . 18 ) are soldered together in the cast state. Cohesive joining connection according to one of claims 1 to 8, characterized in that the aluminum components ( 10 . 12 ) at least in the respective joining area ( 16 . 18 ) consist of the same die-cast aluminum alloy. Cohesive joining connection according to one of claims 1 to 9, characterized in that the joining regions ( 16 . 18 ) of the aluminum components ( 10 . 12 ) are connected together by induction soldering. Cohesive joining connection according to one of claims 1 to 10, characterized in that the aluminum components ( 10 . 12 ) in the respective joining area ( 16 . 18 ) corresponding connection means ( 32 . 34 ) exhibit. Cohesive joining connection according to claim 11, characterized in that the connecting means as in each Fügbereich ( 16 . 18 ) running groove ( 32 ) or spring ( 34 ) are formed. Cohesive joining connection according to claim 11 or 12, characterized in that between the connecting means, in particular between the groove ( 32 ) and the spring ( 34 ), the filler ( 36 ) or the solder is introduced. Method for materially joining two aluminum components ( 10 . 12 ), which in a respective joining area ( 16 . 18 ) are connected to one another by a cohesive joining connection, characterized in that at least in the respective joining area ( 16 . 18 ) aluminum components consisting of a respective die-cast aluminum alloy ( 10 . 12 ) are joined together by a solder joint, in particular by a braze joint. Method according to claim 14, characterized in that aluminum components ( 10 . 12 ) are soldered, which at least in the respective joining area ( 16 . 18 ) consist of a respective aluminum die casting alloy with an iron content of less than 1.0 wt .-% Fe. Method according to claim 15, characterized in that that the joining compound with the help of a non-corrosive Flux is created. Method according to claim 14, characterized in that aluminum components ( 10 . 12 ), which at least in the respective joining area ( 16 . 18 ) consist of a respective aluminum die cast alloy having an iron content of 1.0 to 2.0 wt .-% Fe, and in particular having an iron content of 1.0 to 1.5 wt .-% Fe. Method according to claim 17, characterized in that that the joining compound with the help of a corrosive Flux is created. Method according to one of claims 14 to 18, characterized in that the Fügverbindung with the aid of a filler material ( 36 ) or an aluminum-based solder. A method according to claim 19, characterized in that a filler material ( 36 ) or a solder is used whose melting region is close to below a solidus line of the respective aluminum die-casting alloy of the aluminum components ( 10 . 12 ) lies. Method according to one of claims 14 to 20, characterized in that the two aluminum components ( 10 . 12 ) at least in the respective joining area ( 16 . 18 ) are soldered together in the cast state. Method according to one of claims 14 to 21, characterized in that aluminum components ( 10 . 12 ), which at least in the respective joining area ( 16 . 18 ) consist of the same die-cast aluminum alloy. Method according to one of claims 14 to 22, characterized in that the aluminum components ( 10 . 12 ) are connected together by induction soldering. Method according to one of claims 14 to 23, characterized in that between connecting means, in particular between a groove ( 32 ) and a spring ( 34 ), of the respective joining area ( 16 . 18 ) of the aluminum components ( 10 . 12 ) the filler material ( 36 ) or the solder is introduced. Heat exchangers, in particular for vehicles, with two aluminum components ( 10 . 12 ), which in a respective joining area ( 16 . 18 ) are interconnected by a cohesive Fügverbindung, characterized in that the aluminum components ( 10 . 12 ) at least in the respective joining area ( 16 . 18 ) consist of a respective die-cast aluminum alloy, which are joined together by a solder joint, in particular by a braze joint.