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EP4652009A1 - Tôles à brasage dur, articles formés à partir desdites tôles à brasage dur et procédés de formation d'articles - Google Patents

Tôles à brasage dur, articles formés à partir desdites tôles à brasage dur et procédés de formation d'articles

Info

Publication number
EP4652009A1
EP4652009A1 EP23918012.8A EP23918012A EP4652009A1 EP 4652009 A1 EP4652009 A1 EP 4652009A1 EP 23918012 A EP23918012 A EP 23918012A EP 4652009 A1 EP4652009 A1 EP 4652009A1
Authority
EP
European Patent Office
Prior art keywords
brazing
layer
brazing sheet
aluminum alloy
core layer
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP23918012.8A
Other languages
German (de)
English (en)
Inventor
Farzin FATOLLAHI-FARD
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Arconic Technologies LLC
Original Assignee
Arconic Technologies LLC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Arconic Technologies LLC filed Critical Arconic Technologies LLC
Publication of EP4652009A1 publication Critical patent/EP4652009A1/fr
Pending legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • 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
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/02—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape
    • B23K35/0222—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape for use in soldering, brazing
    • B23K35/0233—Sheets, foils
    • B23K35/0238—Sheets, foils layered
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • 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
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/08—Devices involving relative movement between laser beam and workpiece
    • B23K26/0869—Devices involving movement of the laser head in at least one axial direction
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • 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
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/36—Removing material
    • B23K26/38—Removing material by boring or cutting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • 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
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24—Selection of soldering or welding materials proper
    • B23K35/28—Selection of soldering or welding materials proper with the principal constituent melting at less than 950 degrees C
    • B23K35/286—Al as the principal constituent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • 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
    • B23K37/00—Auxiliary devices or processes, not specially adapted for a procedure covered by only one of the other main groups of this subclass
    • B23K37/04—Auxiliary devices or processes, not specially adapted for a procedure covered by only one of the other main groups of this subclass for holding or positioning work
    • B23K37/0408—Auxiliary devices or processes, not specially adapted for a procedure covered by only one of the other main groups of this subclass for holding or positioning work for planar work
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • 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
    • B23K37/00—Auxiliary devices or processes, not specially adapted for a procedure covered by only one of the other main groups of this subclass
    • B23K37/04—Auxiliary devices or processes, not specially adapted for a procedure covered by only one of the other main groups of this subclass for holding or positioning work
    • B23K37/047—Auxiliary devices or processes, not specially adapted for a procedure covered by only one of the other main groups of this subclass for holding or positioning work moving work to adjust its position between soldering, welding or cutting steps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/01—Layered products comprising a layer of metal all layers being exclusively metallic
    • B32B15/016—Layered products comprising a layer of metal all layers being exclusively metallic all layers being formed of aluminium or aluminium alloys
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C22C21/02—Alloys based on aluminium with silicon as the next major constituent
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C22C21/10—Alloys based on aluminium with zinc as the next major constituent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • 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
    • B23K2101/00—Articles made by soldering, welding or cutting
    • B23K2101/04—Tubular or hollow articles
    • B23K2101/14—Heat exchangers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • 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
    • B23K2101/00—Articles made by soldering, welding or cutting
    • B23K2101/18—Sheet panels

Definitions

  • the present disclosure relates to brazing sheets, articles formed from or including brazing sheets, and methods of forming articles.
  • Various apparatus such as, for example, heat exchangers, may be formed from stacked specially designed metal plates, such as, for example brazing sheets.
  • Plate-type heat exchangers function by circulating two fluids (e.g., liquid, refrigerant, or combinations thereof) on opposite sides of a plate, allowing heat exchange between the fluids.
  • fluids e.g., liquid, refrigerant, or combinations thereof
  • One non-limiting aspect according to the present disclosure is directed to a brazing sheet comprising a brazing layer and a core layer.
  • the brazing layer comprises a 4XXX series aluminum alloy.
  • the core layer comprises a first aluminum alloy comprising, in weight percentages based on total weight of the first aluminum alloy: 0.2 to 0.6 silicon; 1.5 to 2 manganese; 0.01 to 0.2 titanium; 0.5 to 2.5 copper; 0 to 0.5 iron; 0 to 0.5 magnesium; 0 to 0.5 zinc; 0 to 0.3 chromium; 0 to 0.25 zirconium; optionally incidental elements; impurities; and aluminum.
  • the first aluminum alloy satisfies the equation 3.1 ⁇ [Mg], [Fe], [Cr], and [Si] are, respectively, weight percentage concentrations of manganese, iron, chromium, and silicon in the first aluminum alloy.
  • An additional non-limiting aspect according to the present disclosure is directed to an article including, or formed from parts including, a structural element comprising all or a portion of a brazing sheet.
  • the brazing sheet comprises a brazing layer and a core layer.
  • the brazing layer comprises a 4XXX series aluminum alloy.
  • the core layer comprises a first aluminum alloy comprising, in weight percentages based on total weight of the first aluminum alloy: 0.2 to 0.6 silicon; 1.5 to 2 manganese; 0.01 to 0.2 titanium; 0.5 to 2.5 copper; 0 to 0.5 iron; 0 to 0.5 magnesium; 0 to 0.5 zinc; 0 to 0.3 chromium; 0 to 0.25 zirconium; optionally incidental elements; impurities; and aluminum.
  • the first aluminum alloy satisfies the equation 3.1 ⁇ an( j [Mg], [F e ], [ ], an( j [Si] are, respectively, weight percentage concentrations of manganese, iron, chromium, and silicon in the first aluminum alloy.
  • Yet a further non-limiting aspect according to the present disclosure is directed to a method for forming an article of manufacture.
  • the method comprises contacting a first part comprising a first material with a second part comprising all or a portion of a brazing sheet comprising a brazing layer and a core layer.
  • the brazing layer comprises a 4XXX series aluminum alloy.
  • the core layer comprises a first aluminum alloy comprising, in weight percentages based on total weight of the first aluminum alloy: 0.2 to 0.6 silicon; 1.5 to 2 manganese; 0.01 to 0.2 titanium; 0.5 to 2.5 copper; 0 to 0.5 iron; 0 to 0.5 magnesium; 0 to 0.5 zinc; 0 to 0.3 chromium; 0 to 0.25 zirconium; optionally incidental elements; impurities; and
  • [Fe], [Cr], and [Si] are, respectively, weight percentage concentrations of manganese, iron, chromium, and silicon in the first aluminum alloy.
  • the method comprises brazing the first part to the second part by a process comprising at least one of controlled atmospheric brazing and vacuum brazing.
  • FIG. l is a schematic side elevational view of a first non-limiting embodiment of a brazing sheet according to the present disclosure
  • FIG. 2 is a schematic side elevational view of a second non-limiting embodiment of a brazing sheet according to the present disclosure
  • FIG. 3 is a schematic side elevational view of a third non-limiting embodiment of a brazing sheet according to the present disclosure.
  • FIG. 4 is a schematic side elevational view of a fourth non-limiting embodiment of a brazing sheet according to the present disclosure.
  • FIG. 5 is a schematic side elevational view of a fifth non-limiting embodiment of a brazing sheet according to the present disclosure.
  • FIG. 6 is a flow chart illustrating a non-limiting embodiment of a method for forming an article according to the present disclosure.
  • any references herein to “various embodiments”, “some embodiments”, “one embodiment”, “an embodiment”, “a non-limiting embodiment”, or like phrases mean that a particular feature, structure, step, or characteristic described in connection with the example is included in at least one embodiment.
  • appearances of the phrases “various embodiments”, “some embodiments”, “one embodiment”, “an embodiment”, “a non-limiting embodiment”, or like phrases in the specification do not necessarily refer to the same embodiment.
  • the particular described features, structures, steps, or characteristics may be combined in any suitable manner in one or more embodiments.
  • the particular features, structures, steps, or characteristics illustrated or described in connection with one embodiment may be combined, in whole or in part, with the features, structures, steps, or characteristics of one or more other embodiments, without limitation.
  • alloys discussed in connection with the present disclosure optionally include intentional additions of incidental elements that may, for example, aid in production of the alloy and/or improve one or more properties or characteristics of the alloy.
  • certain non-limiting embodiments of alloys according to the present disclosure may include intentional incidental additions of one or more of grain refining elements and/or one or more deoxidizing elements.
  • the total concentration of incidental elements in alloys according to the present disclosure preferably does not exceed 1 weight percent based on the total weight of the alloy, and the concentration of any single incidental element preferably does not exceed 0.2 weight percent based on the total weight of the alloy.
  • impurities are elements or other materials that may be present in relatively minor concentrations in alloys according to the present disclosure but that are not intentionally added to enhance production or affect properties or characteristics of the alloy.
  • impurities in the alloys according to the present disclosure may be present in minor concentrations due to, for example, unavoidable or unintentional presence of the impurities in feed materials, incorporation from the local atmosphere during melting, refining, or other processing, or contamination by contact with processing equipment.
  • the total concentration of impurities in alloys discussed in the present disclosure preferably does not exceed 0.15 weight percent based on the total weight of the alloy, and the concentration of any single impurity preferably does not exceed 0.05 weight percent based on the total weight of the alloy.
  • Brazing sheets typically include alloying elements that would be of value if they can be separated from scrap brazing sheets or from used or scrapped articles of manufacture formed from or including the brazing sheets. Brazing sheets typically include multiple layers, each having its own compositional specifications. It can be challenging to separate layers of a brazing sheet, remove an individual alloying element from a brazing sheet, or separate a layer from an article including or formed from a brazing sheet. As a result, the brazing sheets or articles may have to be recycled as a whole, without separation of layers or regions in which desired elements are present. Certain of the alloying elements in the scrap brazing sheets or scrap articles may be present at concentrations undesirable for use as recycled feed materials in the production of certain aluminum alloy sheets to be incorporated into brazing sheets. For example, some alloying elements may be present in the brazing sheets or scrap articles in concentrations that will adversely affect characteristics of a brazing sheet core layer such as, for example, corrosion resistance, grain size, and/or other microstructural characteristics of the core layer.
  • the present inventor has determined that a balance of chemistry modifications from elements present in scrap material with additional purposeful elemental additions can provide desired properties in aluminum alloy sheets for use in a brazing sheet.
  • the present disclosure provides a brazing sheet that can exhibit advantageous recyclability, along with acceptable or superior formability, corrosion resistance, brazeability, strength, and diffusion resistance.
  • Embodiments of a brazing sheet according to the present disclosure can comprise a brazing layer and a core layer.
  • the brazing layer comprises a 4XXX series aluminum alloy.
  • the core layer comprises a first aluminum alloy comprising, in weight percentages based on total weight of the first aluminum alloy: 0.2 to 0.6 silicon; 1.5 to 2 manganese; 0.01 to 0.2 titanium; 0.5 to 2.5 copper; 0 to 0.5 iron; 0 to 0.5 magnesium; 0 to 0.5 zinc; 0 to 0.3 chromium; 0 to 0.25 zirconium; optionally incidental elements; impurities; and aluminum.
  • the first aluminum alloy satisfies the equation 3.1 ⁇ [Mg], [Fe], [Cr], and
  • [Si] are, respectively, weight percentage concentrations of manganese, iron, chromium, and silicon in the first aluminum alloy.
  • the term “core layer” refers to a substrate layer of the brazing sheet.
  • a “core layer” can be disposed substantially in the center of a brazing sheet.
  • the core layer may or may not be covered on both of its faces with another layer of the brazing sheet and, for example, the core layer can be disposed and partially or fully exposed on one side of the brazing sheet.
  • the core layer of embodiments of a brazing sheet according to the present disclosure can be fully covered on both sides by other layers of the brazing sheet, have at least one side at least partially exposed, or have at least one side fully exposed.
  • a brazing sheet 100 is provided.
  • the brazing sheet 100 comprises a core layer 102 and a brazing layer 104.
  • the core layer 102 and the brazing layer 104 are bonded (e.g., roll bonded) together to form the brazing sheet 100.
  • the brazing sheet 100 illustrated in FIG. 1 includes two layers.
  • the brazing sheet 100 can comprise one or more additional layers, as described herein, such as, for example, three layers as illustrated in FIGs. 2 and 5, four layers as illustrated in FIG. 4, or five layers as illustrated in FIG. 3.
  • the brazing sheet 100 can be subjected to brazing as a step in a production process to form an article of manufacture.
  • a brazing step an assembly comprising a part and the brazing sheet 100 are heated to a temperature that is at least as high as the melting temperature of the brazing layer 104 such that the brazing layer 104 melts and flows to wet a surface of the part and subsequently solidifies to form a suitable braze joint between the brazing sheet 100 and the part.
  • the temperature to which the assembly is heated in the brazing step can be sufficiently high to dissolve soluble phases in the brazing sheet 100.
  • the assembly is heated to a temperature in a range of 590°C to 610°C.
  • the heated assembly is cooled quickly, which can minimize the precipitation of undesirable soluble phases.
  • the core layer 102 can comprise a core layer solidus temperature greater than the brazing temperature to which the brazing sheet 100 is subjected.
  • the core layer 102 can comprise a core layer solidus temperature of at least 600°C, such as, for example, at least 605°C, at least 610°C, or at least 615°C.
  • the core layer 102 can be unhomogenized and H-temper.
  • H-temper has the meaning provided in ANSI H35.1/H35. l(M)-2017.
  • the core layer 102 can develop a brown band, which can be resistant to corrosion.
  • the brown band can form in the core layer 102 when silicon diffuses from the brazing layer 104 to the core layer 102 and forms precipitates with manganese and iron in solid solution during a brazing process.
  • the brown band in the core layer 102 can comprise small-scale Al x Mn y Siz or Alx(Mn,Fe,Cr) y Siz dispersoids that form a band near the interface between the brazing layer 104 and the core layer 102.
  • dispersoids at this interface pulls manganese out of solid solution and creates a more electrochemically negative region in the brazing sheet 100 that is anodic to the center of the brazing sheet 100, thereby increasing the overall corrosion resistance of the core layer 102.
  • silicon in the core layer 102 can affect the formation of a brown band and the core solidus temperature, highly corrosion resistant core layers that contain high levels of silicon typically do not rely on brown band formation for corrosion resistance.
  • the present inventor has determined that silicon, and other alloying elements, can be present in the core layer 102 while achieving desirable brown band formation for enhanced corrosion resistance by adjusting the chemistry of the core layer 102 to compensate for a high level of silicon that may result from using brazing sheet scrap in producing the brazing sheet 100.
  • the core layer 102 of the brazing sheet 100 comprises a first aluminum alloy, such as, for example, a 3XXX series aluminum alloy.
  • the first aluminum alloy can comprise, in weight percentages based on the total weight of the first aluminum alloy, 0.2 to 0.6 silicon, such as, for example, 0.2 to 0.55 silicon, 0.25 to 0.55 silicon, 0.25 to 0.5 silicon, 0.3 to 0.55 silicon, 0.3 to 0.5 silicon, 0.3 to 0.45 silicon, or 0.3 to 0.4 silicon.
  • the silicon content may be derived from the scrap material used in producing the core layer 102.
  • the first aluminum alloy can satisfy the equation X ⁇ [Mg], [Fe], [Cr], and [Si] are, respectively, weight percentage concentrations of manganese, iron, chromium, and silicon in the first aluminum alloy.
  • X can be at least 3.1, such as, for example, at least 3.2, at least 3.3, at least 3.4, at least 3.5, at least 3.6, at least 3.7, at least 3.8, at least 3.9, or at least 4.
  • X can be no greater than 10.
  • X can be in a range of 3.1 to 10.
  • maintaining a suitably high manganese-to- silicon weight ratio in the core layer 102 can allow the core layer 102 to include a substantial amount of scrap material and still exhibit desirable properties.
  • the weight ratio of manganese to silicon in the first aluminum alloy can be at least 3.1, such as, for example, at least 3.2, at least 3.3, at least 3.4, at least 3.5, at least 3.6, at least 3.7, at least 3.8, at least 3.9, or at least 4.
  • the weight ratio of manganese to silicon can be no greater than 10.
  • the weight ratio of manganese to silicon in the first aluminum alloy can be in a range of 3.1 to 10.
  • the first aluminum alloy can comprise, in weight percentages based on the total weight of the first aluminum alloy, 1.5 to 2 manganese, such as, for example, 1.55 to 2 manganese, 1.6 to 2 manganese, 1.65 to 2 manganese, 1.7 to 2 manganese, 1.6 to 1.95 manganese, 1.6 to 1.9 manganese, 1.65 to 1.9 manganese, or 1.65 to 1.85 manganese.
  • 1.5 to 2 manganese such as, for example, 1.55 to 2 manganese, 1.6 to 2 manganese, 1.65 to 2 manganese, 1.7 to 2 manganese, 1.6 to 1.95 manganese, 1.6 to 1.9 manganese, 1.65 to 1.9 manganese, or 1.65 to 1.85 manganese.
  • the first aluminum alloy can comprise, in weight percentages based on the total weight of the first aluminum alloy, 0.01 to 0.2 titanium, such as, for example, 0.03 to 0.2 titanium, 0.05 to 0.2 titanium, or 0.1 to 0.2 titanium.
  • the first aluminum alloy of the core layer 102 can comprise, in weight percentages based on the total weight of the first aluminum alloy: 0.2 to 0.6 silicon; 1.5 to 2 manganese; 0.01 to 0.2 titanium; 0.5 to 2.5 copper; 0 to 0.5 iron; 0 to 0.5 magnesium; 0 to 0.5 zinc; 0 to 0.3 chromium; 0 to 0.25 zirconium; optionally incidental elements; impurities; and aluminum.
  • the first aluminum alloy comprises, in weight percentages based on total weight of the first aluminum alloy: 0.2 to 0.5 silicon; 1.6 to 2 manganese; 0.01 to 0.2 titanium; 0.5 to 1 copper; 0.1 to 0.4 iron; 0 to 0.1 magnesium; 0 to 0.25 zinc; 0 to 0.3 chromium; 0 to 0.25 zirconium; optionally incidental elements; impurities; and aluminum.
  • the first aluminum alloy comprises, in weight percentages based on total weight of the first aluminum alloy: 0.3 to 0.4 silicon; 1.6 to 2 manganese; 0.01 to 0.2 titanium; 0.5 to 1 copper; 0.1 to 0.4 iron; 0 to 0.1 magnesium; 0 to 0.25 zinc; 0 to 0.3 chromium; 0 to 0.25 zirconium; optionally incidental elements; impurities; and aluminum.
  • the chemistry of the core layer 102 can be modified to include another corrosion protection mechanism in addition to or alternatively to a brown band.
  • the core layer 102 can be modified to include a concentration of copper that imparts galvanic protection to the core layer 102. A copper concentration that is too high could undesirably affect properties of the core layer 102.
  • the core layer 102 can comprise a weight ratio of copper to manganese in the first aluminum alloy of no greater than 1, such as, for example, no greater than 0.9, or no greater than 0.8.
  • the core layer 102 can be formed from an ingot comprising, for example, at least 10% scrap material, such as, for example, at least 20% scrap material, at least 30% scrap material, at least 40% scrap material, or at least 50% scrap material.
  • the remainder of the material in the ingot can be feed materials, such as, for example, primary aluminum (e.g., grade P1020) and optionally hardeners.
  • the amount of scrap material included may be balanced based on the amount of silicon or other alloying elements contained in the scrap material.
  • the amount of scrap material and the amount of the feed materials included in a melt to form the ingot for the core layer 102 may be selected such that the resulting core layer 102 includes no greater than 0.6 wt% silicon by weight based on the total weight of the core layer 102.
  • the scrap material can be, for example, pre-consumer waste produced for manufacturing brazing sheets or components thereof (e.g., revert) and/or postconsumer waste obtained from a third party source.
  • the scrap material can comprise, for example, scrap brazing sheets, used or scrapped articles of manufacture formed from or including brazing sheets, and/or scrap material from another source.
  • the brazing layer 104 of the brazing sheet 100 comprises a second aluminum alloy, such as, for example, a 4XXX series aluminum alloy.
  • the second aluminum alloy comprises, in weight percentages based on total weight of the aluminum alloy: 5 to 15 silicon; 0 to 2 magnesium; 0 to 1 iron; 0 to 3 zinc; 0 to 2 copper; 0 to 1 manganese; 0 to 0.3 bismuth; optionally incidental elements; impurities; and aluminum.
  • the brazing layer 104 exhibits a brazing layer solidus temperature that is lower than the core layer solidus temperature, such as, for example, at least 5°C lower, at least 10°C lower, at least 15°C lower, at least 20°C lower, at least 25°C lower, or at least 30°C lower than the core layer solidus temperature. Ensuring that the brazing layer solidus temperature is sufficiently lower than the core layer solidus temperature can enable a brazing process wherein heating the brazing sheet 100 to a suitable temperature melts the brazing layer 104, while the core layer 102 remains substantially solid.
  • each layer in the brazing sheet 100 can be configured based on the desired structural properties of the article (e.g., a heat exchanger) that is to be produced from or that is to incorporate the brazing sheet 100.
  • the core layer 102 can comprise a first thickness, ti, that can be in a range of 60% to 97% of a total thickness (z.e., ttotai) of the brazing sheet 100.
  • the brazing layer 104 can comprise a second thickness, t2, that is in a range of 3% to 20% of the total thickness (ttotai) of the brazing sheet 100.
  • the first thickness, ti is greater than the second thickness, t2.
  • the total thickness (ttotai) of the brazing sheet 100 is in a range of 100 pm to 5 mm, such as, for example, in a range of 200 pm to 1 mm.
  • a brazing sheet according to the present disclosure may comprise one or more layers in addition to a core layer and a brazing layer.
  • a brazing sheet 200 comprises the core layer 102, the brazing layer 104, and a layer 206 disposed on a second side 102b of the core layer 102 opposite a first side 102a of the core layer 102 on which the brazing layer 104 is deposited.
  • the layer 206 may be a second brazing layer configured according to brazing layer 104 described above, or the layer 206 can be a waterside liner.
  • the core layer 102, the brazing layer 104, and the layer 206 are bonded (e.g., roll bonded) together to form the brazing sheet 200.
  • the layer 206 is a second brazing layer
  • the layer 106 and the brazing layer 104 may have the same composition or may have different compositions.
  • the layer 206 is a waterside liner
  • the waterside liner can provide corrosion protection to the brazing sheet 200 and can be in contact with coolant during operation of an article comprising all or a portion of the brazing sheet 200.
  • the waterside liner can comprise a third aluminum alloy comprising, in weight percentages based on total weight of the third aluminum alloy: 0.5 to 12 zinc; 0.1 to 1.2 silicon; 0 to 1 iron; 0 to 0.3 copper; 0 to 1.5 manganese; 0 to 0.6 magnesium; 0 to 0.2 titanium; 0 to 0.2 zirconium; optionally incidental elements; impurities; and aluminum.
  • a brazing sheet according to the present disclosure may comprise one or two interliner layers.
  • a brazing sheet 300 comprises the core layer 102, the brazing layer 104, a layer 206, an interliner layer 308, and an interliner layer 310.
  • the interliner layer 308 is intermediate the brazing layer 104 and the core layer 102
  • the interliner layer 310 is intermediate the layer 206 and the core layer 102.
  • the core layer 102, the brazing layer 104, the layer 206, the interliner layer 308, and the interliner layer 310 are bonded (e.g., roll bonded) together to form the brazing sheet 300.
  • Each of the interliner layers 308 and 310 of the brazing sheet 100 individually comprises a third aluminum alloy.
  • the third aluminum alloy can comprise, in weight percentages based on total weight of the third aluminum alloy: 0.05 to 1.5 silicon; 0 to 2 manganese; 0 to 2 magnesium; 0 to 2 copper; 0 to 0.8 iron; 0 to 3 zinc; 0 to 0.5 zirconium; 0 to 1.0 chromium; 0 to 0.5 bismuth; 0 to 0.3 titanium; optionally incidental elements; impurities; and aluminum.
  • the compositions of the interliner layers 308 and 310 may be the same or different.
  • a brazing sheet according to the present disclosure may not comprise the interliner layer 310, and the layer 206 may be in direct contact with the core layer 102.
  • a brazing sheet 400 comprises the core layer 102, the brazing layer 104, a layer 206, and an interliner layer 308.
  • the core layer 102, the brazing layer 104, the layer 206, and the interliner layer 308 are bonded (e.g., roll bonded) together to form the brazing sheet 400.
  • a brazing sheet according to the present disclosure may not comprise the interliner layer 310 or the layer 206, and the core layer 102 may be exposed on one side.
  • a brazing sheet 500 comprises the core layer 102, the brazing layer 104, and an interliner layer 308.
  • the core layer 102, the brazing layer 104, and the interliner layer 308 are bonded (e.g., roll bonded) together to form the brazing sheet 500.
  • each layer in the brazing sheet 200, brazing sheet 300, brazing sheet 400, and brazing sheet 500 can be configured based on the desired structural properties of the article e.g., a heat exchanger) that is to be produced from or that is to incorporate the brazing sheet 100.
  • the core layer 102 can comprise a first thickness, ti, that can be in a range of 60% to 93% of a total thickness (i.e., ttotai) of the respective brazing sheet 200, 300, 400, or 500.
  • the interliner layers 308 and 310 can comprise a third thicknesses, t3 and t3', and a sum of the two thickness can be in a range of 3% to 30% of a total thickness (ttotai) of the respective brazing sheet 200, 300, 400, or 500.
  • the brazing layers 104 and layer 206 can comprise second thicknesses, t2 and t2', and a sum of the two thickness can be in a range of 3% to 20% of the total thickness (ttotai) of the respective brazing sheet 200, 300, 400, or 500.
  • the first thickness, ti is greater than each second thickness, t2 and t2 r , and also is greater than each third thickness, t3 and t3'.
  • the total thickness (ttotai) of the brazing sheet 200, 300, 400, or 500 is in a range of 100 pm to 5 mm, such as, for example, in a range of 200 pm to 1 mm.
  • the brazing sheet 200 can be suitable for at least one of controlled atmospheric brazing and vacuum brazing.
  • the brazing sheet 200 can comprise layers having compositions so that the brazing sheet 200 is suitable for controlled atmospheric brazing and/or vacuum brazing.
  • magnesium diffusion from the brazing sheet according to the present disclosure may be undesirable as it may interfere with the flux.
  • the brazing sheet according to the present disclosure is configured to inhibit diffusion from the brazing sheet (e.g., inhibit diffusion of magnesium) such that flux can be used in the brazing process.
  • the brazing sheet 100, 200, 300, 400, and 500 according to the present disclosure may have a composition suitable for vacuum brazing (e.g., fluxless vacuum brazing).
  • a composition suitable for vacuum brazing e.g., fluxless vacuum brazing.
  • the brazing sheet 100, 200, 300, 400, and 500 is subjected to flux-free brazing (e.g., brazing in an inert atmosphere with residual O2 in a CAB furnace, without the use of any flux)
  • flux-free brazing e.g., brazing in an inert atmosphere with residual O2 in a CAB furnace, without the use of any flux
  • magnesium diffusion from the brazing sheet can be advantageous, for example, to dissolve an oxide layer formed on the brazing layer 104 and/or facilitate wettability of the surface to be brazed.
  • an article such as, for example, a heat exchanger
  • the heat exchanger can have a galvanic corrosion resistance evaluated under ASTM G85 Annex A3 (2019) of at least 20 days, such as, for example, at least 25 days, or at least 30 days.
  • the heat exchanger can be, for example, an oil cooler, a radiator, a cooling system (e.g., battery cooling system), or a liquid cooled condenser.
  • the article can comprise a tube shape.
  • FIG. 6 provides a block diagram of a non-limiting embodiment of a method according to the present disclosure for forming an article of manufacture such as, for example, a heat exchanger.
  • the method embodiment comprises contacting a first part comprising a first material with a second part comprising all or a portion of a non-limiting embodiment of a brazing sheet according to the present disclosure.
  • a non-limiting embodiment of a method according to the present disclosure may comprise contacting a first part comprising a first material with a second part comprising all or a portion of brazing sheet 100, 200, 300, 400, 500, and/or a different embodiment of a brazing sheet according to the present disclosure (FIG. 4, step 602).
  • the first part can be brazed to the second part by a process comprising at least one of controlled atmospheric brazing and vacuum brazing (FIG. 6, step 604).
  • the first material comprises aluminum or an aluminum alloy.
  • a brazing sheet comprising: a brazing layer comprising a 4XXX series aluminum alloy; and a core layer comprising a first aluminum alloy comprising, in weight percentages based on total weight of the first aluminum alloy,
  • zirconium 0 to 0.25 zirconium; optionally incidental elements; impurities; and aluminum.
  • Clause 4 The brazing sheet of any of clauses 1-3, wherein the first aluminum alloy comprises, in weight percentages based on total weight of the first aluminum alloy:
  • zirconium 0 to 0.25 zirconium; optionally incidental elements; impurities; and aluminum.
  • Clause 7 The brazing sheet of any of clauses 1-6, wherein the 4XXX series aluminum alloy of the brazing layer comprises, in weight percentages based on total weight of the 4XXX series aluminum alloy:
  • Clause 8 The brazing sheet of any of clauses 1-7, wherein the core layer and the brazing layer are bonded together.
  • brazing sheet of any of clauses 1-8 further comprising a waterside liner layer, wherein the core layer is intermediate the waterside liner layer and the brazing layer.
  • zirconium 0 to 0.2 zirconium; optionally incidental elements; impurities; and aluminum.
  • brazing sheet of any of clauses 1-8 wherein: the brazing layer is a first brazing layer disposed on a first side of the core layer; and the brazing sheet further comprises a second brazing layer disposed on a second side of the core layer, opposite the first side of the core layer, wherein the second brazing layer comprises a 4XXX series aluminum alloy.
  • Clause 13 The brazing sheet of clause 12, wherein the core layer, the first brazing layer, and the second brazing layer are bonded together.
  • brazing sheet of claim 12 further comprising a first interliner layer, wherein the first interliner layer is intermediate the core layer and the first brazing layer.
  • Clause 15 The brazing sheet of clause 14, further comprising a second interliner layer, wherein the second interliner layer is intermediate the core layer and the second brazing layer.
  • Clause 16 The brazing sheet of any of clauses 1-11, further comprising an interliner layer, wherein the interliner layer is intermediate the core layer and the brazing layer.
  • brazing sheet of any of clauses 1-16 wherein the brazing sheet has a composition suitable for at least one of controlled atmospheric brazing and vacuum brazing.
  • brazing sheet of claim 1 wherein: the core layer comprises a first thickness in a range of 60% to 97% of a total thickness of the brazing sheet; and the brazing layer comprises a second thickness in a range of 3% to 20% of the total thickness of the brazing sheet.
  • Clause 20 An article of manufacture including, or formed from parts including, a structural element comprising all or a portion of the brazing sheet of any of clauses 1-19.
  • Clause 21 The article of clause 20, wherein the article is a tube-shaped article.
  • Clause 22 The article of any of clauses 20-21, wherein the article comprises a heat exchanger.
  • Clause 23 The article of clause 22, wherein the article has a galvanic corrosion resistance evaluated under ASTM G85 Annex A3 (2019) of at least 20 days.
  • Clause 24 A method for forming an article of manufacture, the method comprising: contacting a first part comprising a first material with a second part comprising all or a portion of the brazing sheet of any of clauses 1-19; and brazing the first part to the second part by a process comprising at least one of controlled atmospheric brazing and vacuum brazing.
  • Clause 25 The method of clause 24, wherein the first material comprises aluminum or an aluminum alloy.
  • Clause 26 The method of claim 23, wherein the article of manufacture is a heat exchanger.
  • zirconium 0 to 0.25 zirconium; optionally incidental elements; impurities; and aluminum.
  • zirconium 0 to 0.25 zirconium; optionally incidental elements; impurities; and aluminum.
  • a brazing sheet comprising: a brazing layer comprising a 4XXX series aluminum alloy; and a core layer comprising a first aluminum alloy comprising, in weight percentages based on total weight of the first aluminum alloy,
  • zirconium 0 to 0.25 zirconium, optionally incidental elements, impurities, and aluminum.
  • a brazing sheet comprising: a brazing layer comprising a 4XXX series aluminum alloy; and a core layer comprising a first aluminum alloy comprising, in weight percentages based on total weight of the first aluminum alloy,
  • any numerical range recited herein includes all sub-ranges subsumed within the recited range.
  • a range of “1 to 10” includes all sub-ranges between (and including) the recited minimum value of 1 and the recited maximum value of 10, that is, having a minimum value equal to or greater than 1 and a maximum value equal to or less than 10.
  • all ranges recited herein are inclusive of the end points of the recited ranges.
  • a range of “1 to 10” includes the end points 1 and 10.
  • Any maximum numerical limitation recited in this specification is intended to include all lower numerical limitations subsumed therein, and any minimum numerical limitation recited in this specification is intended to include all higher numerical limitations subsumed therein. Accordingly, Applicant reserves the right to amend this specification, including the claims, to expressly recite any sub-range subsumed within the ranges expressly recited. All such ranges are inherently described in this specification.

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Abstract

L'invention propose des tôles à brasage dur, des articles formés à partir de la totalité ou d'une partie d'une tôle à brasage dur ou comprenant une telle tôle, et des procédés de formation d'articles manufacturés. La tôle à brasage dur comprend une couche de brasage dur et une couche centrale. La couche de brasage dur comprend un alliage d'aluminium de série 4XXX. La couche centrale comprend un premier alliage d'aluminium comprenant, en pourcentages en poids sur la base du poids total du premier alliage d'aluminium : 0,2 à 0,6 de silicium ; 1,5 à 2 de manganèse ; 0,01 à 0,2 de titane ; 0,5 à 2,5 de cuivre ; 0 à 0,5 de fer ; 0 à 0,5 de magnésium ; 0 à 0,5 de zinc ; 0 à 0,3 de chrome ; 0 à 0,25 de zirconium ; éventuellement des éléments accidentels ; des impuretés ; et de l'aluminium. Le premier alliage d'aluminium satisfait à la formule d'équation (I) et [Mg], [Fe], [Cr] et [Si] sont, respectivement, des concentrations en pourcentage en poids de manganèse, de fer, de chrome et de silicium dans le premier alliage d'aluminium.
EP23918012.8A 2023-01-19 2023-12-12 Tôles à brasage dur, articles formés à partir desdites tôles à brasage dur et procédés de formation d'articles Pending EP4652009A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US202363480625P 2023-01-19 2023-01-19
PCT/US2023/083639 WO2024155383A1 (fr) 2023-01-19 2023-12-12 Tôles à brasage dur, articles formés à partir desdites tôles à brasage dur et procédés de formation d'articles

Publications (1)

Publication Number Publication Date
EP4652009A1 true EP4652009A1 (fr) 2025-11-26

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EP23918012.8A Pending EP4652009A1 (fr) 2023-01-19 2023-12-12 Tôles à brasage dur, articles formés à partir desdites tôles à brasage dur et procédés de formation d'articles

Country Status (5)

Country Link
EP (1) EP4652009A1 (fr)
KR (1) KR20250134069A (fr)
CN (1) CN120187555A (fr)
MX (1) MX2025004925A (fr)
WO (1) WO2024155383A1 (fr)

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7255932B1 (en) * 2002-04-18 2007-08-14 Alcoa Inc. Ultra-longlife, high formability brazing sheet
CN101715380B (zh) * 2007-06-20 2012-12-19 阿勒里斯铝业科布伦茨有限公司 铝合金硬钎焊板材
WO2012125929A1 (fr) * 2011-03-16 2012-09-20 Alcoa Inc. Feuille de brasage multicouche
CN103122428A (zh) * 2011-11-18 2013-05-29 萨帕铝热传输(上海)有限公司 钎焊用铝合金复合管材及其制造方法
US11685973B2 (en) * 2018-06-21 2023-06-27 Arconic Technologies Llc Corrosion resistant high strength brazing sheet

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MX2025004925A (es) 2025-06-02
WO2024155383A1 (fr) 2024-07-25
KR20250134069A (ko) 2025-09-09
CN120187555A (zh) 2025-06-20

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