METHOD FOR MANUFACTURING AN ELECTRICAL CONDUCTOR, SUCH AS A CURRENT ROD, FOR A HIGH-TEMPERATURE ELECTROCHEMICAL DEVICE

Abstract

A method for manufacturing an electrical conductor, such as a current rod, comprising the following successive steps: providing a core made of a first metallic material, providing a sheath made of a second metallic material, the sheath being intended to cover a first part of the core, providing a connection terminal made of a third metallic material, assembling the core and the connection terminal, by crimping, or by crimping and brazing, or by braze welding, or by brazing, assembling the core and the connection terminal with the sheath.

Claims

1. A method of manufacturing an electrical conductor, like a current rod, comprising the following successive steps: providing a core made of a first metallic material, providing a sheath, made of a second metallic material, the sheath being intended to cover a first portion of the core, providing a connection terminal made of a third metallic material, assembling the core and the connection terminal, assembling the core and the connection terminal with the sheath, wherein the sheath is welded on the first portion of the core by hot isostatic pressing, and in that the assembly of the core and of the connection terminal is carried out: by crimping, or by crimping and brazing, or by braze welding, or by brazing.

2. The method according to claim 1, wherein the assembly of the core and of the connection terminal is carried out by crimping and in that the method is carried out by: inserting the core into a counterbore of the connection terminal, so that the connection terminal covers a second portion of the core, crimping the second portion of the core covered by the connection terminal, preferably with a force of 20 kN, covering the first portion of the core with the sheath then welding the sheath on the first portion of the core, by hot isostatic pressing.

3. The method according to claim 1, wherein the assembly of the core and of the connection terminal is carried out by crimping and brazing and in that the method is carried out by: positioning a brazing material in a counterbore of the connection terminal, inserting the core into the counterbore of the connection terminal, so that the connection terminal covers a second portion of the core, crimping the second portion of the core covered by the connection terminal, preferably with a force of 20 kN, carrying out a brazing, so as to melt the brazing material, whereby after cooling of the brazing material, a brazed joint is obtained between the connection terminal and the core, covering the first portion of the core with the sheath then welding the sheath on the first portion of the core, by hot isostatic pressing.

4. The method according to claim 1, wherein the assembly of the core and of the connection terminal is carried out by crimping and brazing and in that the method is carried out by positioning a brazing material in the counterbore of the connection terminal, inserting the core into the counterbore of the connection terminal, so that the connection terminal covers a second portion of the core, crimping the second portion of the core covered by the connection terminal, preferably with a force of 20 kN, covering the first portion of the core with the sheath then welding the sheath (120) on the first portion (111) of the core (110), by hot isostatic pressing, at a temperature high enough to melt the brazing material, whereby simultaneously the hot isostatic pressing is carried out and a brazed joint is obtained between the connection terminal and the core.

5. The method according to claim 1, wherein the assembly of the core and of the connection terminal (130) is carried out by braze-welding and in that the method is carried out by: positioning a brazing material between the connection terminal and the core, carrying out a braze-welding, so as to obtain a braze-welded joint between the connection terminal and the core, covering the first portion of the core by the sheath, the sheath being in contact with the connection terminal then welding the sheath on the first portion of the core, by hot isostatic pressing.

6. The method according to claim 5, wherein the brazing material is an alloy based on copper, zinc and nickel which may further contain silver.

7. The method according to claim 1, wherein the core is made of copper.

8. The method according to claim 1, wherein the sheath is made of stainless steel or of a stainless nickel alloy and in that the connection terminal is made of a stainless alloy.

9. The method according to claim 1, wherein the connection terminal is made of stainless steel.

10. The method according to claim 1, wherein the sheath is made of stainless steel.

11. An electrical conductor, like a current lead, comprising a core, a sheath and a connection terminal, the sheath covering a first portion of the core, wherein the sheath is welded on the first portion of the core, and in that: the core is crimped in the connection terminal, or the core is crimped and brazed in the connection terminal, or the core is braze-welded to the connection terminal by means of a braze-welded joint, the braze-welded joint preferably being an alloy based on copper, zinc and nickel, which may further contain silver.

12. The electrical conductor according to claim 11, wherein the sheath is made of stainless steel or of as stainless nickel alloy and in that the connection terminal is made of a stainless alloy.

13. The electrical conductor according to claim 11, wherein the core is made of nickel, silver, copper or of a copper alloy.

14. The electrical conductor according to claim 11, wherein the core is inserted and crimped into a counterbore of the connection terminal, the connection terminal covering a second portion of the core.

15. The electrical conductor according to claim 11, wherein the core is inserted, crimped and brazed into a counterbore of the connection terminal, the connection terminal covering a second portion of the core.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0073] The present invention will be better understood upon reading the description of embodiments given for purely indicative and non-limiting purposes with reference to the appended drawings wherein:

[0074] FIG. 1, already described before, schematically represents the operating principle of a high-temperature electrolyser (SOEC).

[0075] FIG. 2, already described before, schematically represents the main components of a high-temperature electrolyser (SOEC).

[0076] FIG. 3, already described before, schematically represents an exploded view of a current lead.

[0077] FIGS. 4A and 4B, already described before, schematically represent examples of faults in a current lead, at the whistle/core interface.

[0078] FIG. 5 schematically represents an exploded view of a current lead, according to a particular embodiment of the invention.

[0079] FIG. 6 schematically represents a sectional view of the current lead represented in FIG. 5.

[0080] FIG. 7 schematically represents the pressure exerted during crimping on the periphery of the crimping area of the current lead, according to a particular embodiment.

[0081] FIG. 8 schematically represents an exploded view of a current lead, according to another particular embodiment of the invention.

[0082] FIG. 9 schematically represents a sectional view of the current lead represented in FIG. 8.

[0083] The different portions represented in the figures are not necessarily plotted according to a uniform scale, to make the figures more readable.

DETAILED DISCLOSURE OF PARTICULAR EMBODIMENTS

[0084] Next, even though the description refers, more particularly, to the assembly of a current rod, the invention is generally transposable to assemblies of very resistant metals and/or alloys such as cast irons and special steels. In particular, the invention finds applications for the assembly of steels having poor weldability, the assembly of different metals and alloys, the assembly of galvanised and stainless steels, the assembly of copper and its alloys, the assembly of aluminium and its alloys or to form assemblies with little or no deformations.

[0085] We will now describe the method for manufacturing an electrical conductor, and more particularly, a current rod (also called current lead) with reference to FIGS. 5 to 9.

[0086] The parts to be assembled to form the current rod are the core 110 made of a first metallic material, the sheath 120 made of a second material and the whistle 130 made of a third material.

[0087] The whistle 130 is also commonly called connection terminal.

[0088] The core 110 is a good electrical conductor but is sensitive to oxidation, for example nickel, silver, copper or copper alloys. Preferably, the core 110 is copper. For example, it may consist of Cuc1 or Cua1 copper. The core 110 is a rod.

[0089] The core 110 is inserted into a sheath 120. The sheath 120 is a tube. The sheath comprises first and second ends. On the side of the first end, the sheath 120 covers a first portion 111 of the core 110 (core/sheath overlap area). By its properties of resistance to oxidation which are higher than those of the core 110, it ensures the protection of the latter against the oxidising atmosphere. In this manner, it allows benefiting from the better electrical conductivity of the material of the core by maximising the service life of the assembly in an oxidising atmosphere. For example, the sheath 120 is made of stainless steel or stainless nickel alloy. The second end is intended to be secured with a non-represented endpiece.

[0090] The whistle 130 is intended to be connected to the plate of the electrolyser. It acts as a connection leg and ensures the electrical connection with the electrolyser. It has a shape complementary to the plate of the electrolyser on which it is fastened. The whistle 130 may be pierced (through hole 131) perpendicular to the axis of the sheath so as to be screwed onto the stack of the electrolyser. The whistle 130 may have a geometry other than that illustrated in the figures. For example, it may be cylindrical and intended to fit into a bore or clamped between two half-shells secured to the device to be powered.

[0091] Once assembled to the first end of the sheath 120, the whistle 130 hermetically seals this end, and thus avoids the passage of gas.

[0092] Preferably, the whistle 130 is made of a stainless alloy, for example a nickel-chromium-iron alloy such as Inconel? 600.

[0093] Prior to the assembly of the parts, the preparation of their surfaces is advantageously carried out by a means, or a set of appropriate means (sandblasting, brushing, pickling with detergents and/or solvents in particular).

[0094] According to the invention, the assembly of the core 110, of the sheath 120 and of the whistle 130 to form the electrical conductor may be carried out according to different production processes: crimping, or crimping and brazing or braze-welding, and hot isostatic pressing.

[0095] We will now describe in more detail the first embodiment (assembly by crimping) represented in FIGS. 5, 6 and 7. In this embodiment, a whistle 130 comprising a counterbore 132 will advantageously be used. The counterbore 132 is a blind hole with a flat bottom. The counterbore 132 may have a depth, for example from 8 to 20 mm. The diameter of the counterbore 132 depends on the diameter of the core 110. The core 110 is inserted into the counterbore. Once assembled, the counterbore 132 covers a second portion 112 of the core 110 (core/whistle overlap area). Advantageously, a clearance of 5/100.sup.th is selected between the core and the counterbore of the whistle. Advantageously, the wall of the counterbore 132 is provided with a through hole 133 to enable the evacuation of air during the insertion of the core 110 into the counterbore 132 of the whistle 130.

[0096] Once the core 110 has been inserted into the counterbore 132, crimping is carried out by exerting a pressure on the periphery of the core/whistle overlap area 112 (FIG. 7). The crimping may be carried out with an electromechanical crimping tool. Afterwards, a crimping force, dependent on the effective dimensions of the assembly and the mechanical properties of the material to be crimped, is applied. In the case described herein (Inconel 600 tube, diameter in the range of 10 mm), a force in the range of 20 kN is enough to obtain a satisfactory crimping.

[0097] Afterwards, the sheath 120 is positioned so as to cover the first portion 111 of the core 110. Thus, the core 110 is completely covered on the one hand by the sheath 120 and on the other hand by the whistle 130. Once the whistle 130 and the sheath 120 are brought into contact, they are advantageously welded in order to seal the assembly.

[0098] The crimping being carried out at room temperature (typically between 20 and 25? C.), the molecular structure of the core 110 made of copper is not deformed by heating, which guarantees an extended service life. Crimping is a durable assembly technique.

[0099] We will now describe in more detail the second embodiment (assembly by crimping+brazing).

[0100] According to this second embodiment, it is proceeded as in the first embodiment by further positioning a brazing material in the counterbore in the whistle 130 before inserting the core 110. Preferably, the brazing material is positioned over the flat bottom of counterbore 132. The brazing material 132 (also called filler material) may be in the form of a pellet or a paste that can be spread. Once the core 110 has been inserted into the counterbore 132, the brazing material is in contact with the two parts to be assembled (i.e. with the whistle and the core). The placement of a brazing pellet during mounting with a thickness, preferably comprised between 25 ?m and 200 ?m, and even more preferably 100 ?m, advantageously allows accommodating the defects and creating a connection between the inconel and copper, ensuring electrical continuity.

[0101] The brazing step is carried out by: [0102] heating the two parts 110, 130 and the brazing material up to an assembly temperature higher than the melting temperature of the brazing material, so as to melt the brazing material, and maintaining the assembly temperature for a holding time, the brazing temperature depends on the selected brazing alloy, it is preferably higher than the temperature at which the assembly will be operated, i.e. 900? C. in the case of a current bar of an electrolyser/SOFC fuel cell type system, [0103] cooling the assembly so as to form a brazed joint between the whistle 130 and the core 110, and to assemble them.

[0104] Advantageously, the brazing is carried out during the hot isostatic pressing.

[0105] We will now describe in more detail the third embodiment (assembly by braze-weldingoxyacetylene welding process) represented in FIGS. 8 and 9.

[0106] In this embodiment, the whistle 130 does not comprise a counterbore. It has a shape complementary to the sheath 120: the sheath 120 fits around one of the ends of the whistle 130.

[0107] According to this third embodiment, the assembly is carried out according to the following steps: [0108] positioning the brazing material 140 between the core 110 and the whistle 130, [0109] carrying out a braze-welding of the assembly thus obtained, so as to have an assembly comprising a core 110 connected to the whistle 130 by a braze-welded joint, [0110] inserting the core 110, the braze-welded joint and a portion of the whistle 130 into the sheath 120.

[0111] Preferably, the brazing material 140 is an alloy of copper and zinc. This alloy may further contain silicon.

[0112] For example, a CuZnAg alloy commercialised under the reference 16 XFC? by the company Castolin Eutectic will be selected.

[0113] According to another embodiment, the assembly of the whistle 130 and of the core 110 could be carried out by brazing (without implementing crimping).

[0114] Once the core 110, the sheath 120 and the whistle 130 have been assembled (by crimping and/or by brazing or by braze-welding), this assembly is advantageously subjected to a hot isostatic pressing step in order to weld the sheath 120 to the core 110 and thus reinforce the mechanical strength of the final assembly.

[0115] According to a particular embodiment of the method, diffusion welding by hot isostatic pressing comprises the following steps: [0116] TIG (Tungsten Inert Gas) welding a degassing tube on the second end of the sheath 120, the second end of the sheath 120 being opposite to that one in contact with the whistle 130, [0117] TIG welding a cap (or closure endpiece) to seal this second end. Preferably, the endpiece and its tube are made of a stainless alloy, for example AISI 316L. The endpiece hermetically seals the second end of the sheath 120 except at the degassing central tube which crosses it therethrough and which is in communication with the sheath 120, [0118] placing the sheath under vacuum by pumping via the tube of the first endthis allows drawing the gas present between the core 110 and the sheath 120, [0119] sealing this tube, for example by pinching off the sheath 120, [0120] applying a diffusion welding cycle by hot isostatic pressing (HIP) to the assembly.

[0121] Advantageously, the welding cycle by HIP may comprise the following steps: [0122] bringing the assembly formed by the core 110 and the sheath 120 to a temperature comprised between 600? C. and 1,060? C., preferably between 800? C. and 1,000? C., even more preferably between 900? C. and 1,000? C., in particular a temperature of 920? C.; and [0123] applying on the sheath 120 a pressure comprised between 500 bars and 1,500 bars, preferably between 800 bars and 1,200 bars, in particular a pressure of 1,020 bars, [0124] applying a pressure and temperature level for a period of 30 minutes to several hours, preferably 1 hour to 3 hours, in particular 2 hours, [0125] leaving the assembly to cool and depressurise.

[0126] Advantageously, the current rod 100 is used in an electrochemical system including: [0127] an enclosure for the circulation of air in the volume delimited thereby [0128] an electrochemical device housed in the enclosure (preferably it consists of a high-temperature steam electrolyser or a high-temperature fuel cell), the device comprising: [0129] a stack of elementary electrochemical cells or stack each comprising an electrolyte interposed between a cathode and an anode and connected in series between two electrical terminals, and [0130] two electrical conductors as described before respectively connected to the two electrical terminals.

[0131] Illustrative and non-limiting examples of one embodiment:

[0132] In this example, the 16 XFC? (Cu/Zn/Ag/Ni) brazing material commercialised by Castolin Eutectic is used to make a braze-welded junction between a whistle 130 made of an Inconel? 600 alloy and a core 110 made of copper.

[0133] The brazing material 140 is supplied in the form of a stick coated with an Elastec stripper. The stick has a remarkable flexibility, which allows for an excellent visibility of the melt pool during the assembly operation.

[0134] The brazing material 140 has the following characteristics: 1% Silver/9% Nickel, Solidus: 885? C., Liquidus: 915? C., Tensile strength: 550 MPa, Elastic limit: 236 MPa, Elongation: 35%, Density: 8.4 and Hardness: 120 HB.

[0135] Such a brazing material 140 has high mechanical properties and is particularly suitable for braze-welding steels and cast irons.

[0136] The clearance between the core 110 and the whistle 130 may range, for example, up to 0.1 mm because the alloy has good properties in terms of capillarity.

[0137] Once the braze-welding has been performed, it is proceeded with mounting of the current rod (fitting of the sheath 120 onto the core 110) and the Hot isostatic pressing (HIP) cycle is performed in order to carry out a diffusion welding of the different materials therebetween, without adding a filler metal.