Additive manufacturing of joining preforms

• US 9,969,000 B2
• Filed: 07/08/2015
• Issued: 05/15/2018
• Est. Priority Date: 07/08/2015
• Status: Active Grant

• Current Assignee: GE Infrastructure Technology, LLC (GE Vernova, Inc.)
• Original Assignee: General Electric Company
• Inventors: Witney, Andrew Batton, Breznak, Jeffrey Michael
• Primary Examiner(s): Roe, Jessee R
• Assistant Examiner(s): Mai, Ngoclan T
• Application Number:
  US14/794,712
• Publication Number:
  US 20170008084A1
• Time in Patent Office: 1,042 Days
• Field of Search: None
• CPC Class Codes: B22F 2207/01 Composition gradients
• CPC Class Codes: B22F 2999/00 Aspects linked to processes or compositions used in powder metallurgy
• CPC Class Codes: B22F 5/009 of turbine components other than turbine blades of turbine blades B22F5/04
• CPC Class Codes: B22F 5/10 of articles with cavities or holes, not otherwise provided for in the preceding subgroups
• CPC Class Codes: B22F 7/06 of composite workpieces or articles from parts, e.g. to form tipped tools B22F7/002 takes precedence
• CPC Class Codes: B23K 26/342 Build-up welding
• CPC Class Codes: B23K 26/354 by melting
• CPC Class Codes: B23K 35/0222 for use in soldering, brazing B23K35/0205 takes precedence
• CPC Class Codes: B23K 35/0238 layered
• CPC Class Codes: B23K 35/0244 Powders, particles or spheres; Preforms made therefrom
• CPC Class Codes: B23K 35/262 Sn as the principal constituent
• CPC Class Codes: B23K 35/3006 Ag as the principal constituent
• CPC Class Codes: B23K 35/3013 Au as the principal constituent
• CPC Class Codes: B23K 35/302 Cu as the principal constituent
• CPC Class Codes: B23K 35/3033 Ni as the principal constituent
• CPC Class Codes: B23K 35/3603 Halide salts
• CPC Class Codes: B23K 35/3605 Fluorides
• CPC Class Codes: B23K 35/3606 Borates or B-oxides
• CPC Class Codes: B23K 35/3611 Phosphates
• CPC Class Codes: B23K 35/362 Selection of compositions of fluxes B23K35/365, B23K35/368 take precedence
• CPC Class Codes: B33Y 10/00 : Processes of additive manufacturing
• CPC Class Codes: B33Y 70/00 : Materials specially adapted for additive manufacturing
• CPC Class Codes: Y02P 10/25 : Process efficiency

Abstract

A method of fabricating a joining preform includes the step of printing a self-fluxing joining alloy. Joining includes brazing and soldering. The self-fluxing joining alloy contains at least one of phosphorus, boron, fluorine, chlorine, or potassium. Another printing step prints a non-phosphorous joining alloy. Both printing steps are performed by an additive manufacturing or 3D printing process. The printing a self-fluxing joining alloy step may be repeated until the non-phosphorous joining alloy is substantially encapsulated by the self-fluxing joining alloy. The self-fluxing joining alloy may be a BCuP alloy, a CuP alloy, a CuSnP alloy, a CuSnNiP alloy or a CuAgP alloy. The non-phosphorous joining alloy may be a BAg alloy, a BNi alloy or a BAu alloy.

Claims

1. A method of fabricating a joining preform, the method comprising:

printing a self-fluxing joining alloy, the self-fluxing joining alloy containing at least one of phosphorus, boron, fluorine, chlorine, or potassium, the printing a self-fluxing joining alloy step comprising printing multiple layers of the self-fluxing joining alloy, each of the layers having a different percentage of phosphorus;

printing a non-phosphorous joining alloy;

repeating the printing a self-fluxing joining alloy step until the non-phosphorous joining alloy is substantially encapsulated by the self-fluxing joining alloy; and

wherein both printing steps are performed by an additive manufacturing process.

2. The method of claim 1, wherein the self-fluxing joining alloy is at least one of:

a BCuP alloy, a CuP alloy, a CuSnP alloy, a CuSnNiP alloy or a CuAgP alloy.

3. The method of claim 1, wherein the non-phosphorous joining alloy is at least one of a BAg alloy, a BNi alloy, or a BAu alloy.

4. The method of claim 1, the printing a self-fluxing joining alloy step further comprising:

printing the self-fluxing joining alloy on a part to be joined.

5. The method of claim 1, wherein the joining preform is formed into at least one of:

a cylinder, a disc, a sheet or a washer.

6. The method of claim 1, the multiple layers comprised of a plurality of inner layers and a plurality of outer layers;

and

wherein the outer layers have a different percentage of phosphorus than the inner layers.

7. The method of claim 1, the multiple layers comprised of a plurality of inner layers and a plurality of outer layers;

and

wherein the outer layers have a different melting point than a melting point of the inner layers.

8. A method of fabricating a joining preform, the method comprising:

printing a non-phosphorous joining alloy;

printing a self-fluxing joining alloy on the non-phosphorous joining alloy, the self-fluxing joining alloy containing at least one of phosphorus, boron, fluorine, chlorine, or potassium, the printing a self-fluxing joining alloy step comprising printing multiple layers of the self-fluxing joining alloy, each of the layers having a different percentage of phosphorus; and

wherein both printing steps are performed by an additive manufacturing process.

9. The method of claim 8, wherein the self-fluxing joining alloy is at least one of a BCuP alloy, a CuP alloy, a CuSnP alloy, a CuSnNiP alloy or a CuAgP alloy.

10. The method of claim 9, wherein the non-phosphorous joining alloy is at least one of a BAg alloy, a BNi alloy, or a BAu alloy.

11. The method of claim 9, the printing a non-phosphorous joining alloy step further comprising:

printing the non-phosphorous joining alloy on a part to be joined.

12. The method of claim 9, wherein the joining preform is formed into at least one of:

a cylinder, a disc, a sheet or a washer.

13. The method of claim 8, the multiple layers comprised of a plurality of inner layers and a plurality of outer layers;

and

wherein the outer layers have a higher percentage of phosphorus than the inner layers.

14. The method of claim 8, the multiple layers comprised of a plurality of inner layers and a plurality of outer layers;

and

wherein the outer layers have a different melting point than a melting point of the inner layers.

15. A method of fabricating a brazing preform, the method comprising:

printing a self-fluxing braze alloy, the self-fluxing braze alloy containing phosphorus, the self-fluxing braze alloy is at least one of a BCuP alloy, a CuP alloy, a CuSnP alloy, a CuSnNiP alloy or a CuAgP alloy, the printing a self-fluxing braze alloy step comprising printing multiple layers of the self-fluxing braze alloy, each of the layers having a different percentage of phosphorus;

printing a non-phosphorous braze alloy, the non-phosphorous braze alloy is a BAg alloy;

repeating the printing a self-fluxing braze alloy step until the non-phosphorous braze alloy is substantially encapsulated by the self-fluxing braze alloy; and

wherein both printing steps are performed by an additive manufacturing process, and the brazing preform is formed into at least one of a cylinder, a disc, a sheet or a washer.

16. The method of claim 15, the printing a self-fluxing braze alloy step further comprising:

printing the self-fluxing braze alloy on a part to be brazed.

17. The method of claim 15, the multiple layers comprised of a plurality of inner layers and a plurality of outer layers, the outer layers having a different percentage of phosphorus than the inner layers, and the outer layers having a different melting point than the inner layers.

18. A method of fabricating a joining preform, the method comprising:

printing a self-fluxing alloy in multiple layers, the self-fluxing alloy containing phosphorus, at least some of the layers having a different percentage of phosphorus;

printing a non-phosphorous alloy;

repeating the printing a self-fluxing alloy step until the non-phosphorous alloy is substantially encapsulated by the self-fluxing alloy; and

wherein both printing steps are performed by an additive manufacturing process.

19. The method of claim 18, the multiple layers comprised of a plurality of inner layers and a plurality of outer layers;

and

wherein the outer layers have a different percentage of phosphorus than the inner layers, or the outer layers have a different melting point than a melting point of the inner layers.

20. The method of claim 18, wherein the self-fluxing alloy is at least one of a BCuP alloy, a CuP alloy, a CuSnP alloy, a CuSnNiP alloy or a CuAgP alloy, and the non-phosphorous alloy is at least one of a BAg alloy, a BNi alloy, or a BAu alloy.