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    • 专利摘要:
    METHOD FOR JOINING A FIRST METAL PART WITH A SECOND METAL PART, PRODUCT, AND, FUSION DEPRESSING COMPOSITION Method for joining a first metal part (11) with a second metal part (12), the metal parts (11 , 12) having a solids temperature above 1,000 ° C. The method comprises: applying a melt depressor composition (14) to a surface (15) of the first metal part (11), the melt depressor composition (14) comprising a melt depressor component comprising phosphorus and silicon to decrease a melting temperature of the first metal part (11); placing (202) the second metal part (12) in contact with the melt-depressing composition (14) at a contact point (16) on said surface (15); heating the first and second metal parts (11, 12) to a temperature above 1,000 ° C; and allowing a molten metal layer (210) of the first metal component (11) to solidify, in such a way that a joint (25) is obtained at the point of contact (16). The melt-depressant composition and related products are also described.
    公开号:BR112016001931B1
    申请号:R112016001931-8
    申请日:2014-09-10
    公开日:2020-12-15
    发明作者:Per Sjödin；Kristian Walter
    申请人:Alfa Laval Corporate Ab；
    IPC主号:
    专利说明:

    Field of the Invention
    [001] The invention relates to a method for joining a first metal part with a second metal part using a melt-depressing composition. The invention also relates to the melt-depressant composition and products comprising the joined metal parts. Fundamentals of the Invention
    [002] Nowadays there are different joining methods for metal parts (metal objects or metal parts) that are made of metallic elements, whose metallic elements include several elementary metals, as well as several metallic alloys. The metal parts in question have, by virtue of the metallic elements or alloys they are made of, a melting temperature of at least 1,000oC, which means that the metal parts cannot be made of, for example, pure aluminum or several aluminum-based alloys. Some examples of the metal that the metal parts can be made of are typically alloys based on iron, nickel and cobalt.
    [003] A common method for joining such metal parts is welding, which is a method where the metal in the metal part with or without additional material is melted, that is, a molten product is formed by melting and subsequent re-solidification.
    [004] Another joining method is brazing, which is a metal bonding process, where a filler metal is first applied to at least one of the two metal parts to be joined and is then heated above its melting point and distributed between the metal parts by capillary action. The filler metal is typically taken above its melting temperature, under protection, by a suitable atmosphere. The filler metal flows over the metal parts in order to contact the points where it forms together.
    [005] In general, when brazing, a filler metal is applied in contact with a gap or a space between the metal parts to be joined. During the heating process, the filler metal melts and fills the gap to be joined. In the brazing process there are three main stages, where the first stage is called a physical stage. The physical stage includes wetting and flowing the filler metal. The second stage usually occurs at a given junction temperature. During this stage there is a solid-liquid interaction, which is carried out by substantial mass transfer. A small volume of the metal parts that immediately attach to the liquid addition metal both dissolve and react with the addition metal at this stage. At the same time, a small amount of elements from the liquid phases penetrate the solid metal parts. This redistribution of components in the junction area results in changes in the composition of the filler metal and, sometimes, in the beginning of the solidification of the filler metal. The last stage, which overlaps the second, is characterized by the formation of the microstructure of the final joint and progresses during the solidification and cooling of the joint. The volume of the metal parts that join the liquid addition metal is very small, that is, the junction is largely formed by the addition metal. In general, when brazing, at least 95% of the metal at the junction comes from the filler metal.
    [006] Another method for joining two metal parts (parent materials) is transient liquid phase diffusion bonding (TLP bonding) where diffusion occurs when a melting point depressant element of an interlayer moves at the boundaries of the matrix and grain of the metal parts at the binding temperature. Diffusion processes in the solid state thus lead to a change in the composition at the connection interface and the different interlayer melts at a lower temperature than that of the parent materials. Thus, a thin layer of liquid spreads along the interface to form a joint at a temperature lower than the melting point of any of the metal parts. A reduction in the bonding temperature leads to the solidification of the melting liquid, and this phase can subsequently be diffused out into the metal parts maintaining the bonding temperature for a period of time.
    [007] Joining methods, such as welding, brazing and TLP bonding, successfully connect metal parts. However, welding has its limitations, since it can be very expensive or even impossible to create a large number of joints when they are difficult to access. Brazing also has its limitations, for example, in that it can be difficult to apply properly or determine a more suitable filler metal. TLP bonding is advantageous when it comes to joining different materials, but it has its limitations. For example, it is often difficult to find a suitable interlayer and the method is not very suitable for creating a joint where a large opening must be filled or when a relatively large joint must be formed.
    [008] Thus, many factors are involved in the selection of a certain joining method. Factors that are also crucial are cost, productivity, safety, process speed and properties of the joint that joins the metal parts, as well as properties of the metal parts per se after the joint. Although the methods mentioned above have their advantages, there is still a need for a joining method to be used as a complement to the present methods, particularly if factors such as cost, productivity, safety and speed of the process are taken into account. summary
    [009] It is an objective of the invention to improve previous techniques and prior data. In particular, it is an objective to provide a method for joining metal parts (metal parts, that is, hairs or objects that are made of metal) in a simple and reliable way, while still producing a strong union between the parts of metal.
    [0010] To solve these objectives a method of joining a first metal part with a second metal part is provided. The method is used for metal parts that have a solidus temperature above 1,000 ° C. The method comprises: applying a melt-depressing composition to a surface of the first metal part, the melt-depressing composition comprising a melt-depressing component comprising phosphorus and silicon to decrease a melting point temperature of the first metal part and, optionally, a binder component to facilitate the application of the melt-depressant composition on the surface; placing the second metal part in contact with the melt-depressing composition at a point of contact on said surface; heat the first and second metal parts to a temperature above 1000 ° C, said surface of the first metal part thus melting, in such a way that a surface layer of the first metal part melts and, together with the depressant component from the melting, form a layer of molten (molten) metal that is in contact with the second metal part at the point of contact; and naturally solidify the molten metal layer in such a way that a joint is obtained at the point of contact, the joint comprising at least 50% by weight of metal which, before heating, was part of any of the first metal part and the second part of metal.
    [0011] In one embodiment the joint joint comprises at least 85% by weight of metal, which, before heating, was part of any of the first metal part and the second metal part. This is accomplished by letting the metal from the metal parts flow to the point of contact and form the joint. A joint that is formed in this way is very different from the joints that are formed by brazing, since such joints, in general, comprise at least 90% by weight of metal that, before brazing, was part of a metal a brazing substance that was used to form the joint.
    [0012] In one embodiment, the fusion depressant component comprises at least 8% by weight of phosphorus and in another embodiment the fusion depressant component comprises at least 14% by weight of phosphorus. The melting depressant composition can also be referred to as a melting point depressing composition. The metal in the metal parts can take the form of, for example, metal alloys based on iron, nickel and cobalt, since they typically have a solidus temperature above 1,000 ° C. The metal parts may not be pure aluminum or aluminum-based alloys, which do not have a solidus temperature above 1,000 ° C. The metal in the metal part or even the metal part per se can be referred to as the "parent metal" or "parent material". In this context, an “iron based” alloy is an alloy where iron has the highest percentage by weight of all elements in the alloy (% by weight). The corresponding situation also applies to nickel-, cobalt-, chromium- and aluminum-based alloys.
    [0013] As indicated, the melt-depressing composition comprises at least one component, which is the melt-depressing component. Optionally, the melt-depressing composition comprises a binder component. All substances, or parts of the melt-depressing composition, that contribute to lowering a melting temperature of at least the first metal part are considered to be part of the melt-depressing component. Parts of the melt-depressing composition that are not involved in lowering a melting temperature of at least the first metal part, but instead "bond" to the melt-depressing composition in such a way that it forms, for example , a paste, paint or mud, are considered as part of the binder component. Of course, the fusion-depressing component may include other components, such as small amounts of filler metal. However, such a filler metal may represent no more than 75% by weight of the melt-depressant component, since at least 25% by weight of the melt-depressant component comprises phosphorus and silicon. If a filler metal is included in the melt-depressant composition, it will always be part of the melt-depressant component.
    [0014] In this context, "phosphorus and silicon" means the sum of phosphorus and silicon in the melting depressant component, calculated in% by weight. Here, weight% means weight percentage, which is determined by multiplying the mass fraction by 100. As is known, fraction of the mass of a substance in a component is the ratio of the concentration of the mass of the substance (density of the substance in the component) for the density of the component. Thus, for example, at least 25% by weight of phosphorus and silicon means that the total weight of phosphorus and silicon is at least 25 g in a 100 g sample of melt-depressant component. Obviously, if a binder component is comprised in the melt-depressant composition, then the wt% of phosphorus and silicon in the melt-depressant composition can be less than 25% by weight. However, at least 25% by weight of phosphorus and silicon are always present in the melt-depressant component, which, as indicated, also includes any filler metal that can be included, that is, filler metal is always seen as part of the composition fusion depressor.
    [0015] "Phosphorus" includes all phosphorus in the fusion depressant component, which includes elemental phosphorus, as well as phosphorus in a phosphorus compound. Correspondingly, "silicon" includes all silicon in the melt-depressant component, which includes elemental silicon, as well as silicon in a silicon compound. Thus, both phosphorus and silicon can, in the fusion depressant component, be represented by phosphorus and silicon in various phosphorus and silicon compounds.
    [0016] Obviously, the melt-depressant composition is very different from conventional brazing substances, since they have much more filler metal than melt-depressant substances, such as phosphorus and silicon. In general, brazing substances have less than 18% by weight of phosphorus and silicon.
    [0017] The method is advantageous in that addition metal can be reduced or excluded and in which it can be applied to metal parts that are made of different materials. It can also be used in a wide range of applications, for example, to join heat transfer plates or any suitable metal objects that are otherwise joined, for example, by conventional welding or brazing.
    [0018] Of course, the melt-depressant composition can also be applied to the second metal part.
    [0019] Phosphorus can originate from any elemental phosphorus and phosphorus from a phosphorus compound selected from at least any of the following compounds: manganese phosphite, iron phosphite and nickel phosphite. Silicon can originate from any elemental silicon and silicon from a silicon compound selected from at least any of the following compounds: silicon carbide, silicon boride and ferrosilicon.
    [0020] The fusion depressant component can comprise any of at least 25% by weight, at least 35% by weight and at least 55% by weight of phosphorus and silicon. This means that if any filler metal is present in amounts less than 75% by weight, less than 65% by weight, respectively less than 45% by weight.
    [0021] Phosphorus can make up at least 10% by weight of phosphorus and silicon content of the fusion-depressant compound. This means that, when the melt-depressant component comprises at least 25% by weight of phosphorus and silicon, then the melt-depressant component comprises at least 2.5% by weight of phosphorus. Silicon can make up at least 55% by weight of phosphorus and silicon content of the fusion-depressant compound.
    [0022] The fusion depressant component may comprise less than 50% by weight of metallic elements, or less than 10% by weight of metallic elements. Such metallic elements correspond to the “metal additive” described above. Such small amounts of metallic elements or metal additives differentiate the melt-depressing composition strongly from, for example, known brazing compositions, since they comprise at least 60% by weight of metallic elements. Here, "metallic elements" include, for example, all transition metals, which are the elements in the d-block of the periodic table, which includes groups 3 to 12 in the periodic table. This means that, for example, iron (Fe), nickel (Ni), cobalt (Co), chromium (Cr) and molybdenum (Mo) are "metallic elements." Elements that are not "metallic elements" are the noble gases, halogens and the following elements: boron (B), carbon (C), silicon (Si), nitrogen (N), phosphorus (P), arsenic (As), oxygen (O), sulfur (S), selenium (Se ) and tellurium (Tu). It should be noted that, for example, if the phosphorus comes from the manganese phosphite compound, then the manganese part of this compound is a metallic element that is included in the metallic elements that, in one modality, should be less than 50% by weight and in the other embodiment less than 10% by weight.
    [0023] The first metal part can comprise a thickness of 0.3 to 0.6 mm and the application of the melt-depressant composition can then comprise applying an average of 0.02 to 1.00 mg of phosphorus and silicon per mm2 on the surface of the first metal part. The application of an average of 0.02 to 1.00 mg of phosphorus and silicon per mm2 on the surface of the first metal part includes any indirect application, for example, by means of the second metal part, for example, phosphorus and silicon which is transferred from the second metal part to the first metal part. Thus, the phosphorus and silicon referred to here should not necessarily be applied directly to the first metal part, since it contributes to the melting of the surface layer of the first metal part.
    [0024] The first metal part can comprise a thickness of 0.6 to 1.0 mm and the application of the melt-depressant composition can then comprise applying an average of 0.02 to 1.0 mg of phosphorus and silicon per mm2 on the surface of the first metal part. As previously, the application also includes indirect "application" by means of the second metal part.
    [0025] The first metal part can comprise a thickness of more than 1.0 mm and the application of the melt-depressant composition can then comprise applying an average of 0.02 to 5.0 mg of phosphorus and silicon per mm2 on the surface of the first metal part.
    [0026] The surface may have an area that is larger than an area defined by the contact point on said part of the surface, in such a way that metal in the molten metal layer flows to the contact point allowing the joint to form. Such flow is typically caused by capillary action.
    [0027] The surface area can be at least 3 times larger than the area defined by the contact point. The surface area can be even larger (or the relatively smaller contact point), such as at least 10, 20 or 30 times greater than the area defined by the contact point. The surface area refers to the area of the surface from which the molten metal flows to form the joint.
    [0028] The surface area can be at least 3 or at least 10 times greater than a cross-sectional area of the joint. The surface area can be even larger (or the cross-sectional area of the joint relatively smaller), such that it is at least 6 or 10 times larger than the area defined by the contact point. The cross-sectional area of the junction can be defined as the cross-sectional area that the junction has through a plane that is parallel to the surface where the contact point is located, in a place where the junction has its smallest extension (transversal area).
    [0029] Any of the first metal part and the second metal part can comprise a plurality of projections extending to the other metal part, such that, taking the second metal part in contact with said surface, a plurality of contact point is formed on said surface. This is typically the case when the metal parts are in the form of corrugated plates that are stacked and joined together to form heat exchangers.
    [0030] The first metal part can comprise any of: i)> 50% by weight of Fe, <13% by weight of Cr, <1% by weight of Mo, <1% by weight of Ni and <3% by weight of Mn; ii)> 90% by weight of Fe; iii)> 65% by weight of Fe and> 13% by weight of Cr; iv)> 50% by weight of Fe,> 15.5% by weight of Cr and> 6% by weight of Ni; v)> 50% by weight of Fe,> 15.5% by weight of Cr, 1 to 10% by weight of Mo and> 8% by weight of Ni; vi)> 97% by weight of Ni; vii)> 10% by weight of Cr and> 60% by weight of Ni; viii)> 15% by weight of Cr,> 10% by weight of Mo and> 50% by weight of Ni; ix)> 70% by weight of Co; and x)> 10% by weight of Fe, 0.1 to 30% by weight of Mo, 0.1 to 30% by weight of Ni and> 50% by weight of Co.
    [0031] The former means that the first metal part, and also the second metal part, can be made of a large number of different alloys. Obviously, the previous examples are balanced with other metals or elements, as is common in the industry.
    [0032] According to another aspect, a product comprising a first metal part which is joined with a second metal part by a joint is provided. The metal parts have a solidus temperature above 1,000 ° C and the joint comprises at least 50% by weight of metallic elements that have been removed from an area surrounding the joint and whose area was part of any of the first metal part and the second part of metal.
    [0033] According to another aspect, a product is provided which comprises a first metal part which is joined with a second metal part according to the previous method or any of its modalities.
    [0034] According to another aspect, a melt-depressing composition is provided, that is, specifically to develop and configure to join a first metal part with a second metal part according to the previous method or any of its modalities, the melt-depressant composition comprising i) a melt-depressant component which comprises and silicon to decrease a melting temperature, and ii), optionally, a binder component to facilitate the application of the melt-depressant composition to the first metal part.
    [0035] Different objectives, characteristics, aspects and advantages of the method, the products and the fusion-depressing composition will be evident from the following detailed description, as well as from the drawings. Brief Description Of Drawings
    [0036] Modalities of the invention will now be described, by way of example, with reference to the attached schematic drawings, in which Figure 1 is a cross-sectional view of a first and a second metal part where a melt-depressant composition is applied intermediate to the parts, Figure 2shows the metal parts of Figure 1 during heating, Figure 3shows the metal parts of Figure 1 when a joint is formed, Figure 4is a cross-sectional view of a first and a second metal part where a melt-depressing composition intermediate is applied to the components and when the second metal part touches the first metal part, Figure 5shows the metal parts of figure 4 during heating, Figure 6shows the metal parts of figure 4 when a joint is formed, Figure 7shows parts of metal when a joint is formed and where the parts were pressed towards each other during the formation of the joint, Figure 8 is a view that corresponds Figure 7, where material from both metal parts was melted and formed the joint, Figure 9 corresponds to Figure 1 and shows distribution of a point of contact between the metal parts, Figure 10 shows an area of the point of contact between the parts of metal, Figure 11 corresponds to figure 3 and shows distribution of a joint between the metal parts, Figure 12 shows a cross-sectional area of the joint, Figure 13 shows a pressed plate that is used in countless examples that described how two metal parts can be joined, Figure 14is a photo of a cross section of a joint between the plate shown in figure 13 and a straight plate, Figure 15shows a diagram where a measured joint width is plotted as a function of an applied amount of melt-depressing composition, including trend curves, Figure 16a to 20 show a cross section of a junction investigated in a SEM ((electron scanning microscope) and electron scan locations) and F Figure 21 is a flow chart of a method for joining a first and second metal part. Detailed Description of the Invention
    [0037] Figure 1 shows a first metal part 11 and a second metal part 12 where a melt-depressing composition 14 is arranged on a surface 15 of the first metal part 11. The second metal part 12 is at a point contact 16, in contact with the melt depressor composition 14 on the surface 15. For the second metal part 12 illustrated, a first protrusion 28 is in contact with the melt depressor composition 14 at contact point 16, while a second protrusion 29 is in contact with the melting depressant composition 14 at another contact point 116. The first metal part 11 is made of a metallic element, such as an iron-based alloy. More examples of suitable metal elements that the first metal part 11 can be made of are given below. The second metal part 12 is also made of a metallic element, which can be the same metallic element as the first metal part 11 is made. In figure 1, the first metal part 11 and the second metal part 12 are not yet joined.
    [0038] Five planes, P1 to P5, are used to describe how the first metal part 11 and the second metal part 12 are joined. The first plane P1 defines the surface of the melt depressor composition 14. The second plane P2 defines the surface 15 of the first metal part 11, which is a "top" surface 15 of the first metal part 11. This means that the depressant composition melting point 14 has a thickness that corresponds to the distance between the first plane P1 and the second plane P2 (the surface 15). It should be noted that the thickness of the melt-depressing composition 14 is greatly exaggerated in the figures illustrated. The actual thickness, i.e., the amount of the melt-depressing composition 14 on the surface 15, as well as the composition of the melt-depressing composition 14, is discussed in detail below.
    [0039] The third plane P3 defines a surface layer 21 of the first metal part 11, where the surface layer 21 extends from the surface 15 and to the third plane P3 which is located in the first metal part 11. Thus, the thickness of the surface layer 21 corresponds to the distance between the second plane P2 (the surface 15) and the third plane P3. The fourth plane P4 defines a lower surface of the first metal part 11. The thickness of the first metal part 11 corresponds to the distance between the second plane P2 and the fourth plane P4. The first metal part 11 also has a bottom layer 22, which is a part of the first metal part 11 that does not include surface layer 21 and extends from the third plane P3 to the fourth plane P4. The fifth plane P5 defines a baseline of the second metal part 12, where the first protrusion 28 and second protrusion 29 protrude from the baseline in one direction towards the first metal part 11.
    [0040] The illustrated shapes of the first metal part 11 and the second metal part 12 are only examples and other forms are equally conceivable. For example, the metal parts 11, 12 can be curved in such a way that the planes P1 to P5 are not in the form of straight, two-dimensional surfaces, but rather the shape of the curved surfaces. In particular, the planes P2 and P3 must not be accentuated lines, but can represent gradual transitions.
    [0041] Figure 2 shows the metal components 11, 12 when they are heated to a temperature above which the melt-depressing composition 14 causes the surface layer 21 to melt and form a molten metal layer 210. The temperature it is still below a melting temperature of the materials in the first metal part 11 and the second metal part 12. In summary, heating the metal parts 11, 12, phosphorus and optionally silicon, which is comprised in the melt-depressing composition 14 , diffuses into the first metal part 11 and causes it to melt at a temperature that is less than the melting temperature of the material in the first metal part 11 (and the second metal part 12). The melt depressor composition 14 is applied to the surface 15 in amounts that cause the surface layer 21 to melt and form the molten metal layer 210. Thus, the amount of melt depressor composition 14 is chosen in such a way that phosphorus diffuses only in the surface layer 21 (a lot of phosphor must melt the entire first metal part 11). Suitable compositions and amounts of the melt-depressing composition 14 are described in the examples below. Metal in the molten metal layer 210 then flows, typically by capillary action, to contact point 16 (and to another similar contact point, such as contact point 116).
    [0042] Figure 3 shows the metal components 11, 12 when the entire melt depressor composition 14 diffused into the first metal part 11 and when metal, in the molten metal layer 210, flowed to the point of contact 16 where a junction 25 is now formed. The junction now comprises metal, which was previously part of the first metal part 11. As can be seen, the melt-depressing composition 14 is no longer present on the surface 15 of the first metal part 11, since it was diffused in the first metal part 11 and, typically, to some extent in the second metal part 12. Since junction 25 is formed of metal from the first metal part 11, the first metal part 11 is now at least locally slightly thinner than before heating. As can be seen, the first metal part 11 now has an upper surface 15 'which is not located in the second plane P2. In contrast, the upper surface is now closer to the fourth plane P4. In general, not all of the metal in the molten metal layer 210 flows to the contact point 16 to form junction 25, but some remain as an upper surface of the first metal part 11 and solidify there simultaneously with the solidification of junction 25. A solidification occurs when the temperature is lowered, but also before a temperature decrease, for example, because the phosphorus in the melt-depressing composition gradually diffuses and mixes with the material of the first metal part 11. The physical process behind of the melting of the metal in the first metal part 11, as well as the subsequent solidification is similar to the melting and solidification process that occurs during brazing. However, compared to conventional brazing, there is a big difference in that the melt-depressant composition 14 does not comprise or comprise very small amounts of filler metal; instead of using a filler metal to create junction 25, metal from the first metal part 11 is used to create junction 25. Optionally, as will be described, metal from the second metal part 12 can be used to create junction 25 .
    [0043] Figures 4 to 6 correspond to figures 1 to 3 with the difference that the second metal part 12 is pressed in the melting depressant composition 14 to a point where it is basically in contact with or touching the first metal part 11 (some small amounts of the melt-depressant composition 14 are still typically present between the metal parts 11, 12).
    [0044] Figure 7 corresponds to figures 3 and 6 with the difference that the first metal part 11 and the second metal part 12 were pressed together during the formation of joint 25. As a result, the second metal part 12 at the location of junction 25, "sank" in the molten metal layer 210 of the first metal part 11.
    [0045] Figure 8 corresponds to figure 7, where material from both the first metal part 11 and the second metal part 12 were melted and formed junction 25. In practice, this is typically what happens during the formation of junction 25, especially if the first metal part 11 and the second metal part 12 are made of the same material, since the second metal part 12 is also in contact with the melt-depressing composition.
    [0046] Before heating, the second metal part 12 has an external contour defined by line L2. During heating, a surface layer of the second metal part 12 forms a molten surface layer, where the metal of this layer flows to the contact point 16 and forms a junction 25 therein. The molten surface layer of the second metal part 12 is represented by the layer between line L2 and line L1, where line L1 defines a boundary where the metal of the second metal part 12 has not been melted.
    [0047] It should be noted that there is no real sharp limit between the metal of the first metal part 11 and the second metal part 12 which is melted, respectively, is not melted. On the contrary, there is a gradual "transition" from "cast" to "not cast".
    [0048] Figure 9 corresponds to figure 1 and shows a distribution of the contact point 16 between the first metal part 11 and the second metal part 12. Figure 10 shows the same metal parts 11, 12 but from above and in the first plan P1. Figure 9 is a cross section as seen along line A-A in figure 10.
    [0049] As can be seen, the contact point 16 has a distribution on the melting depressant composition 14 on the first metal part 11 which is significantly greater than a distribution of the melting depressant composition 14 on the surface 15. The distribution of the point contact 16 has an area A2 that is significantly smaller than an area A1 of the melt-depressing composition 14 on surface 15. Area A1 comprises area A2. Area A1 extends between the two lines L3, L4, which are located on the respective side of contact point 16. Line L3 is located between contact point 16 and the other contact point 116, since the metal from the first molten metal part 11, it generally flows to the nearest point of contact. The area A1 of the surface 15 on which the melt-depressing composition 14 is applied is at least 10 times greater than the area A2 defined by the contact point 16. Area A1 can be defined as an area of the surface 15 on which the depressing composition melting point 14 is applied and from which the metal of area A1 is removed to form junction 25. Area A2 can be defined as the area of contact point 16, that is, the area of contact between the melting depressant composition 14 and the second metal part 12, optionally including a contact area (if present) between the first metal part 11 and the second metal part 12 at the contact point 16. Area A1 is, in general, at least 10 times greater than area A2.
    [0050] Figure 11 corresponds to figure 3 and shows a cross-sectional area A3 of junction 25. The area A1 of surface 15 on which the melt-depressant composition 14 is applied is at least 3 times larger than the cross-sectional area A3 of junction 25. Figure 12 shows the same metal parts 11, 12 but from above and in the background P2. Figure 11 is a cross section seen as if along line A-A in figure 12.
    [0051] As can be seen, the junction 25 has a healthy cross section A3 that is significantly smaller than the area A1 of the melt-depressing composition 14 on the surface 15. As previously, area A1 can be defined as a surface area 15 in which the melt-depressing composition 14 is applied and from which the metal A1 area is removed to form junction 25. The cross-sectional area A3 of junction 25 can be defined as the smallest area that junction 25 has between the first metal part 11 and the second metal part 12. The cross-sectional area A3 may be in the form of a curved surface. Of course, areas A1 and A2 may be in the shape of curved surfaces, depending on the respective shape of the first metal part 11 and the second metal part 12.
    [0052] Depending on the shape of the metal parts to be joined, the area in which the melt-depressant composition is applied can be substantially equal to the area of a joint that is subsequently formed
    [0053] Numerous experiments and examples are now presented to describe suitable materials for the first part of metal 11, the second part of metal 12, the composition of the melt-depressing composition 14, whose amounts of the melt-depressing composition 14 are to be used, suitable heating temperatures, for how long the heating should be done, etc. Thus, the results of these experiments and examples are used for entities previously described as the first metal part 11, the second metal part 12, the melting depressant composition 14, the contact point 16, the junction 25 etc., ie , all previously described entities can incorporate related features described in conjunction with the following experiments and examples. In the following, the melt-depressing composition is referred to as a "mixture". Metal part can be referred to as "parent metal".
    [0054] Numerous suitable melt-depressing compositions, i.e., temperature of the melting point depressant composition, have been tested. The active component in the fusion-depressing composition is phosphorus (P). Phosphorus compounds were selected as the source for phosphorus. The compounds include Fe3P, NiP and Mn3P2, where Mn3P2 is a mixture of MnP and Mn2P. Other compounds that include phosphorus can also be used - they just have to be checked for their usefulness and the result they provide, in a similar way to that made for Fe3P, NiP and Mn3P2 and highlighted below.
    [0055] Fe3P, also called iron phosphite, is a conventional compound that was obtained from the company Alfa Aesar, with a CAS number (Chemical Abstracts Service) of 12023-53-9 and MDL number (Molecular Design Limited) of MFCD00799762.
    [0056] Mn3P2, also called manganese phosphite, is a conventional compound that was obtained from the company Alfa Aesar, with a CAS number (Chemical Abstracts Service) of 12263-33-1 and MDL number (Molecular Design Limited) of MFCD00064736.
    [0057] NiP, also called nickel phosphorus, is a conventional compound that has been galvanized into a piece of metal to be joined. The metal part to be joined is also referred to as a base metal or base material. Galvanization was carried out using a conventional nickel phosphorus galvanizing method, as done, for example, by the company Brink Fornicklingsfabriken AB in Norrkoping, Sweden.
    [0058] For some of the examples Si, or Silicon, was used. Silicon is a conventional compound that was obtained from the company Alfa Aesar, it is referred to as “silicon powder, crystalline, mesh-325, 99.5% (metal bases)”, with CAS 7440-21-3 and MDL MFCD00085311.
    [0059] Looking at the atomic compositions of the compounds, applying the atomic weights and using conventional calculation techniques, it can be determined that Fe3P comprises 16% by weight of P (phosphorus) and Mn3P2 comprises 27% by weight of P. In galvanizing with nickel, approximately 11 to 14% by weight of P are comprised in the NiP layer.
    [0060] A binder was used to apply Fe3P and Mn3P2 to the metal parts to be joined. The binder (polymeric and solvent) is a binder sold by Wall Colmonoy under the trade name Nicorobraz S-20 (S-20). A sample of the binder was placed on a metal plate and dried at 22 ° C for 24 hours. The sample weight was 0.56 g before drying and 0.02 g after drying. Thus, 3.57% by weight of the binder are components that remain after drying. A melt-depressant composition was prepared where Mn3P2 and Si form a melt-depressant component (melting point temperature-depressant component) and where S-20 binder forms an agglutinating component. The preparation was done first by mixing Mn3P2 with Si and then adding and mixing the S-20 binder. Two variants of the fusion-depressing composition with different amounts of Si were prepared, referred to as A1 Mn3P2 (A1) and B1 Mn3P2 (B1), as shown in table 1.
    Table 1
    [0061] The compositions A1 and A2 were applied in straight, circular test pieces of stainless steel type 316 L (grade of SAE steel) and with a diameter of 42 mm.
    [0062] In every test piece, another piece of a different material, 254 SMO (grade of SAE steel) was placed. This other part is shown in figure 13 and is in the form of a circular, pressed plate 150, which is 42 mm in diameter and has a thickness of 0.4 mm. The pressed plate 150 has two pressed bundles v and h, each approximately 20 mm long. When the piece with the bundles was placed on the straight piece, contact points were formed where the bundles of the piece 150 touch the other straight piece.
    [0063] The pieces, that is, the straight circular piece and the pressed plate, are referred to as a sample, and several samples were heat treated for 2 hours under vacuum at different temperatures for each sample. Table 2 shows what quantities of the compositions were used for the samples.
    [0064] For samples A1: 1 to A1: 3 and samples B1: 1 to B1: 3, the heat treatment included keeping the samples at a temperature of 1,120 ° C for 2 hours in a vacuum.
    [0065] For samples A1: 4 to A1: 6 and samples B1: 4 to B1: 6, the heat treatment included keeping the samples at a temperature of 1,140 ° C for 2 hours in a vacuum.
    [0066] A1 indicates composition A1 Mn3P2, while B2 indicates composition B1 Mn3P2. The numbers after A1, respectively B2, indicate different samples, as shown in table 2. In this table, the weight of the sample is shown, which includes the weight of the melt-depressant component and the weight of the dry binder component.
    Table 2
    [0067] After the heat treatment, the samples were naturally cooled to room temperature (22 ° C) and it was observed that the two pieces of the sample were joined along the lengths of the pressed plate 150, that is, the sample has junctions along the beams. The samples were cut through the joints in two sections and each joint was measured as its widest X section, which is illustrated in figure 14. The results are shown in table 3 and illustrated in the diagram in figure 15, where the width of the joint is plotted as a function of the amount of melt-depressant composition applied.

    Table 3
    [0068] Metallurgical investigations were then made for the joints. This was done by analyzing the cross-section of the junctions in a so-called SEM-EDX, which is a conventional and commercially available electron scanning microscope with an X-ray detector. Figure 16 illustrates the locations of three measurements for sample A1-6 and table 4 shows the results of the measurements.
    Table 4
    [0069] Investigations show that the joints comprise at least 90% by weight of metal, which, before heating, was part of any of the first metal part and the second metal part, that is, the sample pieces. This is readily determined, since Mn and P together represent less than 2.2% by weight.
    [0070] Similar investigations were also done for sample B1-6. Figure 17 illustrates the locations of three measurements for sample B1-6 and Table 5 shows the results of the measurements.
    Table 5
    [0071] Investigations show that the joints comprise at least 90% by weight of metal, which, before heating, was part of any of the first metal part and the second metal part, that is, the sample pieces. This is readily determined, since Mn and P together represent less than 4.2% by weight.
    [0072] In a following test, 316 stainless steel parts, referred to as 316, with a diameter of 42 mm were applied with three different melt-depressing compositions (one composition in a respective piece): i) Mn3P2, ii) NiP galvanized in 316 and iii) NiP galvanized in 316 together with Si as melting point depressants. The thickness of the galvanized NiP is 50 μm. 0.15 g of Si was applied by conventional painting. In every part, a pressed part similar to that of figure 13 of type 254 SMO was placed. The pieces form samples that were heat treated for 2 hours in a vacuum at 1,120 ° C. Joints were formed between the pieces.
    [0073] Table 6 shows an analysis of a cross-section cut of the joints using SEM-EDX for the sample with 50 μm NiP galvanizing. From the result, it appears that the joint comprises at least 20% by weight of metal which, before heating, was part of either part (first part of metal) or second part (second part of metal). measurement location at the junction.

    Table 6
    [0074] Table 7 shows an analysis of a cross-section of the joints using SEM-EDX for the sample with 50 μm NiP galvanization where approximately 0.15 g of Si was applied (painted) on the galvanized surface. From the result, it appears that the joint comprises more metal, compared to the test where no Si was used. A greater amount of Si could more likely increase the amount of metal in the joint that comes from the test pieces. Figure 19 shows the location of measurements at the junction.
    Table 7
    [0075] Table 8 shows an analysis of a cross-section of the joints using SEM-EDX for the sample with Mn3P2. Mn3P2 was mixed 50p: 50p with S-20 binder, but no Si is used. An amount of 0.2 g (after drying the binder component) was applied. From the result, it appears that the joint comprises at least 80% by weight of metal, which before joining was part of the products that were joined. Figure 20 shows the location of spectrum 1 measurements at the junction.
    Table 8 Method
    [0076] Referring to figure 21 a flow chart of a method for joining a first and second metal part is illustrated. The metal parts can be made of different materials as previously described.
    [0077] In a first step 201, the melt-depressant composition is applied to the surface of one of the metal parts (here the first metal part). The application per se can be done by conventional techniques, for example, by spraying or painting, in the case that the melt-depressing composition comprises an agglutinating component, and by PVD or CVD, in the case where the agglutinating component is not used.
    [0078] In the next step 202, the second metal part is brought into contact with the melt-depressing composition at a point of contact on the surface. This can be done manually or automatically using conventional, automated manufacturing systems.
    [0079] In a next step 303, the metal parts are heated to a temperature that is above 1,000 ° C. The exact temperature can be found in the examples below. During heating, a surface of at least the first molten metal part and, together with the melting depressant component, forms a layer of molten metal that is in contact with the second metal part at the point of contact between the first part of metal and the second metal part. When this happens, metal from the molten metal layer flows to the point of contact.
    [0080] In the final step 204, the molten metal layer solidifies naturally, in such a way that a junction is obtained at the contact point, that is, the metal that flowed to the contact point solidifies. Solidification typically includes lowering the temperature to normal room temperature. However, solidification also occurs during the physical process of component redistribution (phosphorus and, optionally, silicon) in the junction area, before a temperature is lowered.
    [0081] From the foregoing description, it follows that, although various modalities of the invention have been described and shown, the invention is not restricted to it, but can also be incorporated in other ways within the scope of the subject in question defined in the claims that follow. Various fusion-depressing compositions can also be combined with various metals for the metal parts.
    权利要求:
    Claims (15)
    [0001]
    1. Method for joining a first metal part (11) with a second metal part (12), the metal parts (11, 12) having a solidus temperature above 1000 ° C, characterized by the fact that the method comprises -apply (201) a melt-depressing composition (14) to a surface (15) of the first metal part (11), the melt-depressing composition (14) comprising -a melt-depressing component comprising at least 25% in weight of phosphorus and silicon to decrease a melting temperature of the first metal part (11), and-optionally, a binder component to facilitate the application (201) of the melt-depressing composition (14) on the surface (15), and - optionally, a filler metal which is present in amounts less than 75% by weight - placing (second) the second metal part (12) in contact with the melt-depressing composition (14) at a contact point (16) in the said surface (15), - heat (203) the first and second metal parts (11, 12) to a temperature above 1000 ° C, said surface (15) of the first metal part (11) thus merges, in such a way that a surface layer (21) of the first metal part (11) melts and, together with the fusion-depressing component, form a layer of molten metal (210) which is in contact with the second metal part (12) at the contact point (16), and - allow (204) that the molten metal layer (210) solidify and form a joint (25) at the contact point (16), the joint (25) comprising at least 50% by weight of metal which, before heating (203), was part of any of the first metal part ( 11) and the second metal part (12).
    [0002]
    2. Method according to claim 1, characterized by the fact that the phosphorus originates from a phosphorus compound selected from at least any of the following compounds: MnxPy, FexPy and NixPy.
    [0003]
    Method according to claim 1 or 2, characterized by the fact that silicon originates from any elementary silicon and silicon from a silicon compound selected from at least any of the following compounds: silicon carbide, silicon boride and ferrosilicon.
    [0004]
    Method according to any one of claims 1 to 3, characterized in that the melt-depressant component comprises any of at least 35% by weight of and at least 55% by weight of phosphorus and silicon.
    [0005]
    Method according to any one of claims 1 to 4, characterized by the fact that phosphorus constitutes at least 10% by weight of the phosphorus and silicon content of the fusion-depressant compound.
    [0006]
    Method according to any one of claims 1 to 5, characterized by the fact that silicon constitutes at least 55% by weight of phosphorus and silicon content of the fusion-depressant compound.
    [0007]
    Method according to any one of claims 1 to 6, characterized in that the melt-depressing component comprises less than 50% by weight of metallic elements.
    [0008]
    Method according to any one of claims 1 to 7, characterized in that the melt-depressing component comprises less than 10% by weight of metallic elements.
    [0009]
    Method according to any one of claims 1 to 8, characterized in that the first metal part comprises a thickness of 0.3 to 0.6 mm and the application (201) of the melt-depressing composition (14) it comprises applying an average of 0.02 to 1.00 mg of phosphorus and silicon per mm2 on the surface (15) of the first metal part (11).
    [0010]
    Method according to any one of claims 1 to 8, characterized in that the first metal part comprises a thickness of 0.6 to 1.0 mm and the application (201) of the melt-depressing composition (14) it comprises applying an average of 0.02 to 2.0 mg of phosphorus and silicon per mm2 on the surface (15) of the first metal part (11).
    [0011]
    Method according to any one of claims 1 to 10, characterized in that the surface (15) has an area (A1) that is larger than an area (A2) defined by the contact point (16) on said surface (15), in such a way that the metal in the molten metal layer (21 ') flows to the point of contact (16) allowing (204) the junction (25) to form.
    [0012]
    12. Method according to claim 11, characterized by the fact that the area (A1) of the surface (15) is at least 3 times greater than the area (A2) defined by the contact point (16).
    [0013]
    13. Method according to claim 11 or 12, characterized in that the area (A1) of the surface (15) is at least 10 times greater than a cross-sectional area (A3) of the joint (25).
    [0014]
    Method according to any one of claims 1 to 13, characterized in that any of the first metal part (11) and the second metal part (12) comprises a plurality of protrusions (28, 29) extending to the other metal part, such that by placing (202) the second metal part (12) in contact with said surface (15), a plurality of contact points (16, 116) is formed on said surface (15).
    [0015]
    Method according to any one of claims 1 to 14, characterized in that the first metal part comprises one of> 50% by weight of Fe, <13% by weight of Cr, <1% by weight of Mo , <1 wt% Ni and <3 wt% Mn,> 90 wt% Fe,> 65 wt% Fe and> 13 wt% Cr,> 50 wt% Fe,> 15.5% by weight of Cr and> 6% by weight of Ni,> 50% by weight of Fe,> 15.5% by weight of Cr, 1 to 10% by weight of Mo and> 8% by weight of Ni,> 97% by weight of Ni,> 10% by weight of Cr and> 60% by weight of Ni,> 15% by weight of Cr,> 10% by weight of Mo and> 50% by weight of Ni, > 70% by weight of Co,> 80% Cu, and> 10% by weight of Fe, 0.1 to 30% by weight of Mo, 0.1 to 30% by weight of Ni and> 50% by weight of Co .
    类似技术:
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    BR112016001931B1|2020-12-15|METHOD FOR JOINING A FIRST METAL PART WITH A SECOND METAL PART
    JP6444960B2|2018-12-26|Method for joining metal parts
    KR20220012910A|2022-02-04|Method for joining metal parts
    同族专利:
    公开号 | 公开日
    DK2853333T3|2019-11-18|
    US20160199931A1|2016-07-14|
    US10180292B2|2019-01-15|
    ES2756850T3|2020-04-27|
    CL2015003755A1|2016-10-07|
    SI2853334T1|2017-12-29|
    PH12016500192B1|2016-05-16|
    MX2015017579A|2016-04-21|
    PL2853333T3|2020-02-28|
    EP2853333B1|2019-08-21|
    KR20160058921A|2016-05-25|
    JP6290384B2|2018-03-07|
    CA2916342C|2018-10-09|
    SG11201600189SA|2016-04-28|
    IL243428D0|2016-02-29|
    PH12016500192A1|2016-05-16|
    CN105555452B|2019-04-02|
    ES2654532T3|2018-02-14|
    RU2633171C1|2017-10-11|
    AR097770A1|2016-04-13|
    EP2853333A1|2015-04-01|
    KR102123503B1|2020-06-16|
    KR20160060707A|2016-05-30|
    AR100759A1|2016-11-02|
    US10323890B2|2019-06-18|
    US20160202005A1|2016-07-14|
    JP6250165B2|2017-12-20|
    CN105829002B|2018-09-25|
    NZ715303A|2017-09-29|
    BR112016001931A2|2017-08-01|
    JP2016533267A|2016-10-27|
    SA516370799B1|2020-06-11|
    WO2015043945A1|2015-04-02|
    KR101874214B1|2018-07-03|
    PT2853333T|2019-12-02|
    SI2853333T1|2019-12-31|
    TW201519986A|2015-06-01|
    AU2014327554B2|2017-02-02|
    WO2015043944A1|2015-04-02|
    CN105829002A|2016-08-03|
    CA2916342A1|2015-04-02|
    JP2016536144A|2016-11-24|
    EP2853334A1|2015-04-01|
    DK2853334T3|2018-01-15|
    CN105555452A|2016-05-04|
    EP2853334B1|2017-10-25|
    TWI602636B|2017-10-21|
    KR20180100709A|2018-09-11|
    AU2014327554A1|2016-04-07|
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    法律状态:
    2018-11-06| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2019-08-13| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|
    2020-08-11| B06A| Patent application procedure suspended [chapter 6.1 patent gazette]|
    2020-10-13| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2020-12-15| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 10/09/2014, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    EP13186257.5|2013-09-26|
    EP13186257.5A|EP2853333B1|2013-09-26|2013-09-26|Method of joining metal parts using a melting depressant layer|
    PCT/EP2014/069240|WO2015043945A1|2013-09-26|2014-09-10|Method for joining metal parts|
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