SHAPING OF AMORPHOUS METAL ALLOYS

Abstract

Disclosed is a method of brazing articles together to form at least one braze defined by complementarily curved faying surfaces on the articles, the faying surfaces each having at least one region of curvature comprising at least one point from which the surface curves in more than one direction, the method comprising the steps of: a) disposing between the complementarily curved faying surfaces at least one amorphous brazing alloy preform of complementary curvature at least in part to said at least one region of the complementarily curved faying surfaces to conform to the complementarily curved faying surfaces in said region; and b) heating the articles and at least one amorphous brazing alloy preform to a brazing temperature at which the amorphous brazing alloy flows and brazes. and brazing alloy preforms for use in such methods. Methods of forming an article comprising a curved surface from a sheet of an amorphous metal alloy are disclosed, by applying heat from a fluid to a sheet of the amorphous metal alloy to raise at least a portion of the sheet to a temperature above the glass transition temperature T.sub.g and below the crystallization temperature T.sub.x.

Claims

1. A method of brazing articles together to form at least one braze defined by complementarily curved faying surfaces on the articles, the complementarily curved faying surfaces each having at least one region of curvature comprising at least one point from which the surface curves in more than one direction, the method comprising the steps of: a) disposing between the complementarily curved faying surfaces at least one amorphous brazing alloy preform of complementary curvature at least in part to said at least one region of the complementarily curved faying surfaces to conform to the complementarily curved faying surfaces in said region; and b) heating the articles and at least one amorphous brazing alloy preform to a brazing temperature at which the amorphous brazing alloy flows and brazes.

2. A method as claimed in claim 1 in which steps a) and b) are separated by transitional process steps.

3. A method as claimed in claim 1, in which initial process steps precede step a).

4. A method as claimed in claim 1, in which succeeding process steps follow step b).

5. A method as claimed in claim 1, in which at said at least one point from which the surface curves in more than one direction, the radius of curvature is at least 3 mm in each said direction.

6. A method as claimed in claim 5, in which at said at least one point from which the surface curves in more than one direction, the radius of curvature is at least 50 mm in each said direction.

7. A method as claimed in claim 1, in which the amorphous brazing alloy preform has dimensions in two orthogonal directions of greater than 100 mm.

8. A method of forming an article comprising a curved surface from a sheet of an amorphous metal alloy, having a glass transition temperature T.sub.g and crystallization temperature T.sub.x, the article comprising a surface having at least one region of curvature comprising at least one point from which the surface curves in more than one direction, the method comprising the step of applying heat from a fluid to a sheet of the amorphous metal alloy to raise at least a portion of the sheet to a temperature above the glass transition temperature T.sub.g and below the crystallization temperature T.sub.x, for a time sufficient to permit the sheet to deform to form the at least one region of curvature.

9. A method as claimed in claim 8, in which the fluid applies pressure to the sheet to deform the sheet.

10. A method as claimed in claim 8, in which the sheet deforms to make contact with a mold surface complementary to the at least one region of curvature.

11. A method as claimed in claim 8, in which the article comprising a curved surface is a brazing metal preform and the amorphous metal alloy is an amorphous metal brazing alloy.

12. A method as claimed in claim 8, in which at said at least one point from which the surface curves in more than one direction, the radius of curvature is at least 3 mm in each said direction.

13. A method as claimed in claim 12, in which at said at least one point from which the surface curves in more than one direction, the radius of curvature is at least 50 mm in each said direction.

14. A method as claimed in claim 8, in which the article has dimensions in two orthogonal directions of greater than 100 mm.

15. A brazing metal preform comprising a sheet of an amorphous metal brazing alloy comprising a surface having at least one region of curvature comprising at least one point from which the surface curves in more than one direction with a radius of curvature in each said direction of at least 3 mm.

16. A brazing metal preform as claimed in claim 15, comprising a part cylindrical section and a part conical section.

17. A brazing metal preform as claimed in claim 15, comprising a cylindrical section and a conical section.

18. A brazing metal preform as claimed in claim 15, comprising a domed section and a flat section.

19. A brazing metal preform as claimed in claim 15, in which at said at least one point from which the surface curves in more than one direction, the radius of curvature is at least 50 mm in each said direction.

20. A brazing metal preform as claimed in claim 15, in which the amorphous brazing alloy preform has dimensions in two orthogonal directions of greater than 100 mm.

21. A brazing metal preform as claimed in claim 15, mounted to a support.

22. A product formed at least in part using the method of claim 1.

23. A product formed at least in part using the method of claim 8.

Description

[0026] Further features of the invention are as set out in the claims and exemplified in the following description with reference to the drawings in which:-

[0027] FIG. 1 is a schematic view of two articles to be brazed together

[0028] FIG. 2 is an expanded schematic view of the articles of FIG. 1 additionally showing a conventional method of brazing

[0029] FIG. 3 is a schematic view of the articles of FIG. 1 additionally showing a brazing metal preform in accordance with the present invention;

[0030] FIGS. 4-7 schematically show apparatus for forming complex curved articles and the process for forming complex curved articles.

[0031] FIG. 8 is a photograph of a foil curved in accordance with the invention.

[0032] FIG. 9 is a photograph of a foil curved in accordance with the invention.

[0033] Articles 1,2 comprise a convex protrusion 3 on article 1 and a concave depression 4 in article 2. The convex protrusion 3 and concave depression 4 have complementary curvature such that when the convex protrusion 3 and concave depression 4 are engaged there is only a narrow gap sufficient to receive a brazing foil.

[0034] Conventionally, amorphous metal foils are cut into a plurality of shapes 5 that are fitted together in a mosaic pattern to match the contours of complementarily curved faying surfaces such as are defined at least in part by the concave depression 4.

[0035] In contrast, in one aspect, the present invention provides an amorphous metal brazing alloy preform shaped to have a complementary form to the complementarily curved faying surfaces on the articles. As indicated in FIG. 3, an amorphous metal brazing alloy preform 6 comprises or consists of a domed region 7 matching the contours of the convex protrusion 3 and concave depression 4. It should be noted that the invention is not limited to surfaces that are entirely curved but also encompasses surfaces that are curved in part and flat in part.

[0036] Such a preform can be made by deforming a sheet of the amorphous metal at a temperature above the glass transition temperature T.sub.g and below the crystallization temperature T.sub.x, for a time sufficient to form the at least one region of complementary curvature.

[0037] Typically, an amorphous metal foil is heated above the foil T.sub.g in a tool with a desired conformal shaped surface on one side and applying a uniform force to the non-conformal foil face after a the T.sub.g has been exceeded by a suitable amount. The force may be applied through gravity; with a complementarily shaped tool; by a deformable bladder; by blow moulding or any other process that permits the metal to deform to the desired shape. By performing operations on the heated amorphous metal foil at a temperature above T.sub.g and below T.sub.x reconfiguring from a flat foil to a shaped preform (foil) is accomplished while amorphous properties are maintained.

[0038] As mentioned above, T.sub.g and T.sub.x depend upon the alloy used. Experimentally determined T.sub.g ranges for the alloys mentioned above are tabulated below:-

TABLE-US-00001 Liquidus Solidus T.sub.g ° C. Alloy ° C. ° C. nominal 56.55% Ni, 30.5% Pd, 10.5% Cr, 977 941 200-230 and 2.45% B (Palnicro ™ -30) 73.8% Ni, 14.0% Cr, 4.5% Si, 4.5% 1094 960 230-260 Fe, and 3.2% B (Icronibsi ™ - 14) 82.3% Ni, 7.0% Cr, 4.5% Si, 3.2% 1024 969 215-250 B, and 3.0% Fe (Icronibsi ™ - 7).

[0039] As indicated above, T.sub.x varies according to time exposed to temperature. For example, for the above alloys, forming at times less than about 15-20 minutes at a temperature within the above T.sub.g ranges preserves amorphous qualities within the foil, although the invention is not restricted to that range. Lot chemistry is known to produce pronounced changes in the liquidus and solidus temperatures. Similarly T.sub.g does vary with chemistry.

[0040] Typically, a mold/fixture surface of a negative shape contour is made from any material suitable for the temperature used in the glass phase forming. Provision for heating the foil can be either in the mold/fixture or alternately heating may be done in an oven/furnace either in atmosphere/vacuum/air/or suitable fluid medium as determined by the alloy to be formed. The heating method used must provide precision and control for repeatability. A useful method is by supplying heat and pressure to the foil by delivering heat from a fluid (for example a liquid, gas, supercritical fluid or plasma), Useful fluids for this purpose include saturated steam or superheated steam since these allow rapid delivery of heat to the alloy in a controllable manner. The use of fluids to deliver the heat to the foil provides a relatively uniform delivery of heat across the foil. It is useful in forming to hold immobile the edges and/or other regions where shaping/deformation will not occur.

[0041] Following heating of the foil to above the T.sub.g of foil to be shaped, pressure applied to the foil forces it into contact with the surface of the desired shape of the negative contour. During forming the foil stretches and flows with some thinning while in the glass like state, however with suitable temperature control between T.sub.g and T.sub.x, amorphous quality of the foil is maintained as is a great degree of the metal foil like flexibility. Pressure may be applied by a variety of means, but where a fluid is used for heating (as claimed herein), the fluid can also be used to provide pressure to the foil, to deform the foil once it is above T.sub.g. It should be noted that the viscosity of the amorphous metal does not need to be as low as in WO2011/127414 for this process to work, and forming and cooling of the deformed amorphous metal sheet can be performed while retaining predominantly amorphous character to the sheet.

[0042] The scalability of heating with fluids permits large products to be made, for example having dimensions in two orthogonal directions of greater than 100 mm.

[0043] FIGS. 4 and 5 shows a simple curved tool 11 curving about one axis A: a complex curved tool 12 having a surface 13 that curves about two axes B,C; and an amorphous foil 14.

[0044] FIG. 5 shows the foil 14 being applied to conform to the simple curve of the underside of the simple curved tool 11.

[0045] FIG. 6 shows a section of simple curved tool 11, amorphous foil 14 and complex curved tool 12. A gap 15 is shown between the simple curved tool 11 and complex curved tool 12 that is a consequence of their differing curvatures. Pressure applied to urge the simple curved tool 11 towards complex curved tool 12 results in the foil 14 being held at each end where the simple curved tool 11 and complex curved tool 12 abut. Other means of retaining the edges of the foil 14 may be envisaged, for example dedicated clamps.

[0046] The foil in the assembly of simple curved tool 11, amorphous foil 14 and complex curved tool 12 is then exposed to a temperature above the glass transition temperature T.sub.g and below the crystallization temperature Tx, for a time sufficient for the foil to deform to match the surface of the complex curved tool 12, to form at least one region of curvature comprising at least one point from which the surface curves in more than one direction.

[0047] The curvature at the at least one point from which the surface curves in more than one direction can be of any desired value that in combination with the size of the foil does not result in excessive thinning of the foil. Contrary to the limitations of U.S. Pat. No. 6,551,421 , the radius of curvature is not limited to small values such as not more than approximately 1 mm. Accordingly the present disclosure claims brazing alloy foils having a radius of curvature in each direction at the at least one point from which the surface curves in more than one direction of at least 3 mm: curvatures of at least 10 mm, or at least 50 mm, or at least 100 mm, or at least 1 meter, or even more can be accommodated. Other points on the preform may have radii of curvature of less than 3 mm.

[0048] For some alloys gravity may be enough to permit the foil to slump to conform to the complex curved tool 12. For others pressure may be required to be applied. Pressure can be applied in many ways, for example:- [0049] by providing a deformable simple curved tool 11 and applying pressure to its upper surface; [0050] by providing a bladder between the simple curved tool 11 and amorphous foil 14 and supplying fluid under pressure to the bladder so that it distends to deform the amorphous foil 14; [0051] by providing fluid channels in the simple curved tool 11 communicating with the curved face against which the amorphous foil 14 is applied and supplying a fluid under pressure through the fluid channels to deform the amorphous foil 14.

[0052] [In the latter cases, the fluid under pressure may also be the means of supplying the heat as is described further below with reference to FIG. 9].

[0053] FIG. 7 shows the foil 14 in the deformed state, held at its edges by the simple curved tool 11 and complex curved tool 12 and lying adjacent the complex curved tool 12.

[0054] FIG. 8 shows a preform formed in accordance with the invention and comprising a generally cylindrical portion 8 and a generally conical portion 9. The preform was formed from Icronibsi-7™ at a forming temperature of 240° C. The foil was at temperature for 40 minutes and subsequently cooled to room temperature to produce an amorphous foil preform. Wrinkles 10 show the flexible nature of the preform but in use the foil would conform to a surface comprising a cylinder leading into a cone.

[0055] FIG. 9 shows an amorphous metal brazing alloy preform formed in accordance with the invention and comprising a generally domed portion 11 having a radius of curvature of approximately 625 mm and a generally flat portion 12. The radius of the base of the dome was approximately 90 mm and the center of the dome stood approximately 6.5 mm above the flat portion.

[0056] The preform was formed from a foil of Icronibsi-7™ at a forming temperature nominally 240° C. Heat and pressure were supplied through use of superheated steam from a steam generator with steam pressures in the range around 7-105 kPa (1-15 psi) above atmospheric, to deform part of the sheet to conform to a mold of complementary form to the domed portion.

[0057] Multiple cycles of heat and pressure were applied over a period of minutes to test both the apparatus and the effect of cycling on the foil. Multiple cycles need not be used in production, but in some cases may be of assistance in making complex shapes [e.g. by conforming the same or different portions of the foil to different molds]. The mold was permitted to cool naturally, but forced cooling can be of assistance, and in a production environment would both shorten cycle times and reduce the risk of crystallization,

[0058] Although superheated (dry) steam was used in this example, any fluid with sufficient heat content flowing in appropriate quantities can be used to controllably raise the temperature of the amorphous metal with suitable heating rates and limiting heating to above the T.sub.g without markedly changing the amorphous properties through excessive crystallization. Steam is just the most convenient fluid in most cases.

[0059] More complex shapes [e.g. bowls, elliptical surfaces, spherical surfaces, toroidal surfaces] can be made in like manner. It should be noted that at the junction between the cone and cylinder the surface of the preform curves in two directions, around the circumference of the cylinder, and along the axis of the cylinder. In this respect it should be noted that in the present specification the term “curves” includes discontinuous curves such as linear sections extending in different directions from a point.

[0060] The formed preform can be supplied alone, or if too flexible and delicate for safe transport, mounted to a support [which may be a removable part of the mold/fixture surface].

[0061] The formed preform permits easy assembly with the articles to be brazed and provides predictable and good contact with the faying surfaces, so permitting either conventional joints when raised above the alloy liquidus, or intimate contact as required for diffusion joining.

[0062] A typical alloy preform would have a thickness between but not restricted to ˜12.7 μm [0.0005″] to ˜76.2 μm [0.003″], with a length and width restricted only by the forming process of the sheet of amorphous metal brazing alloy from which it is formed.

[0063] An alloy preform may have perforations located to match intended no-braze regions to effect joint voids after suitable forming and after brazing.

[0064] An alloy preform may extend beyond the faying surfaces.

[0065] An alloy preform may be shaped or machined adding additional features that will be maintained after brazing.

[0066] For large curved surfaces more than one curved preform may be mosaicked to cover the surface.

[0067] Further features, variants, and modifications to the invention disclosed herein will be evident to the person skilled in the art. In particular, although the above disclosure refers largely to brazing alloys, it will be evident that other amorphous metals can be formed into curved forms in like manner and used in appropriate applications where the particular properties of amorphous metals are useful, and where the combination of complex curved shapes and amorphous metal properties provide benefits.

[0068] Such applications include but are not restricted to electronics, medicine, optics, heating, corrosion, or tribology, where combining amorphous metal material properties and shape improve and expand functionality.

[0069] Specific examples include but are not limited to:- [0070] Formed shapes for hydrogen separating membranes for fuel cells. [0071] Formed shapes as part of a laminate structure for making jet engine blades and vanes [0072] Formed shapes of amorphous Inconel and Titanium alloys for high temp aero structures of jet engine blades and vanes. [0073] Formed shapes for shape memory alloys used in implantable and surgical medical apparatus and devices. [0074] Formed shapes for Li-Ion battery components. [0075] Formed shapes for membrane screens used to disperse or propel powders or bioloical agents via vibration. [0076] RFID tags [0077] Hard drive pick up heads [0078] Brazing alloy preforms for use in brazing diamond to carbide or other substrates.

[0079] The invention further includes articles formed by brazing using the brazing metal preforms described above or claimed herein.

[0080] It is to be noted that use of the term “invention” is not intended to restrict the scope of the new and inventive technologies hereby disclosed and the applicant reserves the right to claim any or all new and inventive technologies hereby disclosed.