U.S. patent application number 14/482729 was filed with the patent office on 2015-02-26 for method of brazing articles of stainless steel.
This patent application is currently assigned to Alfa Laval Corporate AB. The applicant listed for this patent is Alfa Laval Corporate AB. Invention is credited to Jens Rassmus, Per Erik Sjodin.
Application Number | 20150053389 14/482729 |
Document ID | / |
Family ID | 37452285 |
Filed Date | 2015-02-26 |
United States Patent
Application |
20150053389 |
Kind Code |
A1 |
Sjodin; Per Erik ; et
al. |
February 26, 2015 |
METHOD OF BRAZING ARTICLES OF STAINLESS STEEL
Abstract
The present invention relates to a method of brazing articles of
stainless steel, which method comprises the following steps: step
(i) applying an iron-based brazing filler material to parts of
stainless steel; step (ii) optionally assembling the parts; step
(iii) heating the parts from step (i) or step (ii) to a temperature
of at least about 1000.degree. C. in a non-oxidizing atmosphere, a
reducing atmosphere, vacuum or combinations thereof, and heating
the parts at the temperature of at least about 1000.degree. C. for
at least about 15 minutes; step (iv) providing articles having an
average hardness of less than about 600 HV1 of the obtained brazed
areas. The present invention relates also to brazed articles of
stainless steel.
Inventors: |
Sjodin; Per Erik; (Lund,
SE) ; Rassmus; Jens; (Malmo, SE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Alfa Laval Corporate AB |
Lund |
|
SE |
|
|
Assignee: |
Alfa Laval Corporate AB
Lund
SE
|
Family ID: |
37452285 |
Appl. No.: |
14/482729 |
Filed: |
September 10, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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11915184 |
Feb 7, 2008 |
8857699 |
|
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PCT/SE06/00618 |
May 24, 2006 |
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14482729 |
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Current U.S.
Class: |
165/185 ;
228/219; 228/220; 228/221; 428/682 |
Current CPC
Class: |
B22F 2009/041 20130101;
Y10T 428/12347 20150115; F28F 9/00 20130101; B23K 2101/14 20180801;
B23K 1/008 20130101; B22F 9/04 20130101; B22F 9/082 20130101; C22C
38/002 20130101; B23K 35/30 20130101; B23K 1/0008 20130101; B23K
1/0012 20130101; B32B 15/011 20130101; F28F 21/083 20130101; C22C
38/54 20130101; B23K 1/19 20130101; Y10T 428/12979 20150115; Y10T
428/12958 20150115; F28F 21/089 20130101; F28D 9/00 20130101; B23K
35/3053 20130101; Y10S 165/905 20130101; C22C 38/34 20130101 |
Class at
Publication: |
165/185 ;
428/682; 228/219; 228/220; 228/221 |
International
Class: |
B23K 1/19 20060101
B23K001/19; B23K 1/00 20060101 B23K001/00; B23K 35/30 20060101
B23K035/30; F28F 9/00 20060101 F28F009/00 |
Foreign Application Data
Date |
Code |
Application Number |
May 26, 2005 |
SE |
0501198-6 |
May 26, 2005 |
SE |
0501199-4 |
Claims
1. A brazed article of stainless steel comprising at least about
one base material of stainless steel and an iron-based brazing
filler material wherein the obtained brazed areas, pores, cracks,
gaps, joints, or crevices having a tensile strength of at least
about 110 N/mm.sup.2.
2. A brazed article of stainless steel comprising at least about
one base material of stainless steel and an iron-based brazing
filler material wherein the obtained brazed areas, pores, cracks,
gaps, joints, or crevices having an average hardness less than
about 600 HV1.
3. The article of stainless steel according to claim 1, wherein the
parts or the articles obtained in step (iv), are selected from
reactors, separators, columns, heat exchangers, or equipments for
chemical plants or food plants, or for car industry.
4. The article of stainless steel according to claim 2, wherein the
parts or the articles obtained in step (iv), are selected from
reactors, separators, columns, heat exchangers, or equipments for
chemical plants or food plants, or for car industry.
5. The article of stainless steel according to claim 1, wherein the
article is being brazed heat exchanger plates, brazed reactor
plates, or combinations thereof.
6. The article of stainless steel according to claim 2, wherein the
article being brazed heat exchanger plates, brazed reactor plates,
or combinations thereof.
7. The article of stainless steel according to claim 5, wherein the
article having a burst pressure of at least about 60 Bar.
8. The article of stainless steel according to claim 6, wherein the
article having a burst pressure of at least about 60 Bar.
9. The article of stainless steel according to claim 7, wherein the
article having a burst pressure of at least about 80 Bar.
10. The article of stainless steel according to claim 8, wherein
the article having a burst pressure of at least about 80 Bar.
11. The article according to claim 1, wherein the article is a heat
exchanger having a heat exchanger plate area larger than about 0.20
m.sup.2, a burst pressure of at least about 65 Bar, and a porthole
area of at least about 0.003 m.sup.2.
12. The article according to claim 2, wherein the article is a heat
exchanger having a heat exchanger plate area larger than about 0.20
m.sup.2, a burst pressure of at least about 65 Bar, and a porthole
area of at least about 0.003 m.sup.2.
13. The article of stainless steel according to claim 1, wherein
the brazed areas, pores, cracks, gaps, joints, or crevices having a
silicone content of at least about 2 wt % Si.
14. The article of stainless steel according to claim 2, wherein
the brazed areas, pores, cracks, gaps, joints, or crevices having a
silicone content of at least about 2 wt % Si.
15. The article of stainless steel according to claim 1, wherein
the brazed areas, pores, cracks, gaps, joints, or crevices having a
tensile strength of at least about 120 N/mm.sup.2.
16. The article of stainless steel according to claim 2, wherein
the brazed areas, pores, cracks, gaps, joints, or crevices having a
tensile strength of at least about 120 N/mm.sup.2.
17. The article of stainless steel according to claim 1, wherein
the article is a heat exchanger having a plate pack of at least
about three heat exchanger plates brazed together in one brazing
cycle having the following steps: (i) applying an iron-based
brazing filler material to heat exchanger plates of stainless
steel; (ii) assembling the heat exchanger plates to a plate pack;
(iii) heating the plate pack to a temperature of at least about
500.degree. C. to equalise the temperature in the plate pack and
then raising the temperature to at least about 1000.degree. C. in a
non-oxidizing atmosphere, a reducing atmosphere, vacuum or
combinations thereof, and let the plate pack be brazed together at
the temperature of at least about 1000.degree. C. for at least
about 15 minutes; and (iv) providing articles having an average
hardness of less than about 600 HV1 of the obtained brazed
areas.
18. The article of stainless steel according to claim 2, wherein
the article is a heat exchanger having a plate pack of at least
about three heat exchanger plates brazed together in one brazing
cycle having the following steps: (i) applying an iron-based
brazing filler material to heat exchanger plates of stainless
steel; (ii) assembling the heat exchanger plates to a plate pack;
(iii) heating the plate pack to a temperature of at least about
500.degree. C. to equalise the temperature in the plate pack and
then raising the temperature to at least about 1000.degree. C. in a
non-oxidizing atmosphere, a reducing atmosphere, vacuum or
combinations thereof, and let the plate pack be brazed together at
the temperature of at least about 1000.degree. C. for at least
about 15 minutes; and (iv) providing articles having an average
hardness of less than about 600 HV1 of the obtained brazed
areas.
19. The article of stainless steel according to claim 17, wherein
the article is a heat exchanger having a plate pack up having more
than nine heat exchanger plates brazed together in one brazing
cycle having the following steps: (i) applying an iron-based
brazing filler material to heat exchanger plates of stainless
steel; (ii) assembling the heat exchanger plates to a plate pack;
(iii) heating the plate pack to a temperature of at least about
1000.degree. C. to equalise the temperature in the plate pack and
then raising the temperature to at least about 1150.degree. C. in a
non-oxidizing atmosphere, a reducing atmosphere, vacuum or
combinations thereof, and let the plate pack be brazed together at
the temperature of at least about 1150.degree. C. for at least
about 15 minutes; (iv) providing articles having an average
hardness of less than about 600 HV1 of the obtained brazed
areas.
20. The article of stainless steel according to claim 18, wherein
the article is a heat exchanger having a plate pack up having more
than nine heat exchanger plates brazed together in one brazing
cycle having the following steps: (i) applying an iron-based
brazing filler material to heat exchanger plates of stainless
steel; (ii) assembling the heat exchanger plates to a plate pack;
(iii) heating the plate pack to a temperature of at least about
1000.degree. C. to equalise the temperature in the plate pack and
then raising the temperature to at least about 1150.degree. C. in a
non-oxidizing atmosphere, a reducing atmosphere, vacuum or
combinations thereof, and let the plate pack be brazed together at
the temperature of at least about 1150.degree. C. for at least
about 15 minutes; (iv) providing articles having an average
hardness of less than about 600 HV1 of the obtained brazed areas.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The instant application is a divisional application of and
claims priority to U.S. patent application Ser. No. 11/915,184,
filed Feb. 7, 2008, which is a National Stage Application of and
claims priority to PCT/SE06/000618, filed May 24, 2006, which
claims priority to Swedish Patent Application Nos. 0501199-4 and
0501198-6, both filed on May 26, 2005. The aforementioned patent
applications are incorporated by reference in their entireties
herein.
[0002] The present invention relates to a method of brazing
articles of stainless steel, and the invention relates further to
an article of stainless steel.
BACKGROUND OF INVENTION
[0003] Sealing of crevices and pores, and brazing of joints are
important factors when producing brazed articles, especially when
producing fluid tight articles without leakage. When the joints,
crevices and pores are large in area, then the ability of sealing
and filling increases its importance for the braze filler, but
ability to seal and fill is not necessarily linked to the strength
of the brazed zone or area. Therefore, one requirement is to
provide articles, which have enough strength for the intended
purpose or use. Different methods for brazing are developed and are
described for instance in U.S. Pat. No. 6,109,505 and U.S. Pat. No.
4,516,716, which documents disclose brazing of stainless steel.
THE INVENTION
[0004] In accordance with one aspect of this invention there is
provided a method of brazing or soldering articles of stainless
steel. Hereinafter brazing is used, but it should be understood
that the term also comprises soldering, and that the material of
the invention comprises soldering material and brazing material.
Thus, the method of brazing comprises: step (i) applying an
iron-based brazing filler material to parts of stainless steel;
step (ii) optionally assembling the parts; step (iii) heating the
parts from step (i) or step (ii) to a temperature of at least about
1000.degree. C. in a non-oxidizing atmosphere, a reducing
atmosphere, vacuum or combinations thereof, and heating the parts
at the temperature of at least about 1000.degree. C. for at least
15 minutes; step (iv) providing articles having an average hardness
of less than about 600 HV1 (Vickers hardness test--Part 1: Test
method (ISO 6507-1:1997)) of the obtained brazed areas; and step
(v) optionally repeating one or more of step (i), step (ii) and
step (iii).
[0005] According to an alternative aspect of the present invention
there is provided a method of brazing articles of stainless steel,
which comprises a method having an alternative step (iv) comprising
sealing or filling joints, pores, cracks, gaps, or crevices larger
than about 76 .mu.m.
[0006] The present invention relates further to an article of
stainless steel obtained by the method, wherein the obtained brazed
areas, joints, pores, cracks, gaps, or crevices having a tensile
strength of at least about 110 N/mm.sup.2.
[0007] The present invention relates further to an article of
stainless steel obtained by the method, wherein the obtained brazed
areas, joints, pores, cracks, gaps, or crevices having an average
hardness less than 600 HV1.
[0008] Even though the thermal expansion coefficient is the same
for a small object and a large object of the same material, the
larger object will have a larger total expansion. If one of two
objects, with the same length at the same temperature, is heated,
the difference in length will be proportional to the size of the
object for the same difference in temperature. Both of those facts
give rise to larger crevices, which brazing filler materials have
to be able to fill. Thus, large size, i.e. area, length, broadness,
thickness etc. of a metal object, has an effect on accuracy of
brazed joints or brazed areas, since thermal expansion of the parts
will differ, and may give rise to uneven fitness and large
crevices. Other cases of uneven fitness may be caused by design of
parts to be assembled, to movements when brazing the objects, or by
manufacture of parts to be assembled. Therefore, one important
aspect when brazing joints or areas etc. is the capability to fill
and seal when brazing.
[0009] Copper (Cu) has good capability to seal large crevices. One
of the reasons for not using Cu brazed objects is the limitation of
the properties of the Cu braze-filler, e.g. Cu can induce different
types of corrosion problems. The most obvious problem is that
copper is consumed due to corrosion. The consummation of copper can
decrease the mechanical strength of the object and the object can
begin to leak. The release of Cu corrosion products and Cu-ions
into the media in an object can give rise to galvanic corrosion in
other parts of the same system where the object is installed.
Silver braze-filler might be an option, but is normally not used
since the price for silver is high.
[0010] Nickel (Ni) braze-fillers containing chromium (Cr) have
better corrosion resistance than Cu braze-fillers, but Ni
braze-fillers have some disadvantages. One of those is that nickel
can be released from the nickel braze when used in water
applications. The amount of nickel in tap water is limited by
legislation. Ni-ions can also give rise to galvanic corrosion in
other parts of the same system where the object is installed.
[0011] An important issue for the strength is the size of the
crevices or gaps the brazing filler material is able to fill. The
capability of nickel braze-fillers to fill crevices is limited and
nickel brazing materials can also loose strength in large crevices,
i.e. crevices larger than 0.076 mm. Thus, large Ni-brazed objects
are difficult to produce.
[0012] The selection of a particular brazing filler metal for a
specific application depends on a variety of factors. Basic
considerations are temperature and the materials to be brazed. In
any brazing process the brazing filler material must possess a
solidus temperature that is high enough to provide the required
properties to the brazed assembly. The process needs a liquidus
temperature which is low enough to be compatible with the
temperature capabilities of the parts to be joined. In accordance
with one aspect of this invention there is provided a method of
producing articles of stainless steel by brazing a base material of
stainless steel with an alloy having mainly the same composition as
the base material, thus providing a homogenized joint of the alloy
between the base material or base materials. The brazing alloy
comprises iron as the main component, and the alloy can be an
iron-based alloy or an iron-based brazing filler material. The
iron-based brazing filler material can be produced by gas- or water
atomization, by melt spinning, mechanical alloying or by the
crushing of ingots.
[0013] When brazing a joint it is suitable that the brazing
material wets parts of the objects, which are to be brazed
together, and that the brazing material can flow into crevices,
joints, pores etc. during brazing. The melting point of the brazing
filler material is suitable below the melting point of the base
material of the parts. A relevant property of the brazing filler
material is the capability to fill crevices, joints, pores etc. The
nickel-based brazing materials have inferior capability of filling
crevices, thus large size objects such as large Ni-brazed heat
exchangers are very hard to produce.
[0014] The brazing material can be manufactured as a sheet, a
powder, or a powder mixed with a binder forming a paste, or the
brazing material may be dispersed in a mixture of binder and
liquid, which can be painted or sprayed on a surface of base
material.
[0015] The iron-based brazing filler material may be applied as a
powder or as a paste one way may be to apply strings or drops of
iron-based brazing filler material by pressing it through a nozzle.
Another way of applying the iron-based brazing filler material may
be to apply a binder in form of drops or strings on the base
material and then scatter brazing powder over the surface.
[0016] The method of the invention comprises the following steps:
[0017] step (i) applying an iron-based brazing filler material to
parts of stainless steel; [0018] step (ii) optionally assembling
the parts; [0019] step (iii) heating the parts from step (i) or
step (ii) to a temperature of at least 1000.degree. C. in a
non-oxidizing atmosphere, a reducing atmosphere, vacuum or
combinations thereof, and heating the parts at the temperature of
at least 1000.degree. C. for at least 15 minutes; [0020] step (iv)
providing articles having an average hardness of less than 600 HV1
of the obtained brazed areas; and [0021] step (v) optionally
repeating one or more of step (i), step (ii) and step (iii).
[0022] According to one alternative aspect of the invention
comprises the method the following steps: [0023] step (i) applying
an iron-based brazing filler material to parts of stainless steel;
[0024] step (ii) optionally assembling the parts; [0025] step (iii)
heating the parts from step (i) or step (ii) to a temperature of at
least 1000.degree. C. in a non-oxidizing atmosphere, a reducing
atmosphere, vacuum or combinations thereof, and heating the parts
at the temperature of at least 1000.degree. C. for at least 15
minutes; [0026] step (iv) sealing or filling joints, pores, cracks,
gaps, or crevices larger than 76 .mu.m; and [0027] step (v)
optionally repeating one or more of step (i), step (ii) and step
(iii).
[0028] The method according to another alternative aspect may also
comprise repeating step (i), and applying the iron-based brazing
filler material to one or more additional parts, or to the articles
provided in step (iv); and assembling in step (ii) the parts or
articles from repeating step (i) with one or more additional parts,
or with the articles provided in step (iv), and repeating step
(iii) and step (iv). This aspect enables the manufacture of
articles having a complex design, which have to be brazed in a
stepwise fashion.
[0029] According to another alternative aspect, the method
comprises step (iii) heating to a temperature of at least
1100.degree. C. According to yet another alternative aspect, the
method comprises step (iii) heating to a temperature of at least
1150.degree. C. The heating may be carried out for less than 15
minutes according to one alternative aspect. According to another
alternative aspect of the invention objects are brazed for at least
15 minutes at a temperature above 1100.degree. C., and longer
brazing times are also relevant for many applications. The parts or
articles may be heated to the temperature at which the brazing
material melts. The method of the invention may comprise a step
(iii) which includes preheating the parts to for example a
temperature at least 400.degree. C., at least 500.degree. C. or
even at least 550.degree. C. and leaving the parts at that
temperature for example for at least 15 minutes, at least 30
minutes, at least 1 hour, or even longer, then raising the
temperature to for example at least 900.degree. C., at least
1000.degree. C. or even at least 1100.degree. C. the parts are left
at this temperature to equalise the temperature in the parts so
that the temperature is equal throughout the parts and brazing
material. The time to equalise depends on the size of the article
to be brazed, for smaller objects a shorter time may be sufficient.
Suitable times may be for example at least one hour, at least 2
hours, at least 3 hours, or even longer. The temperature depends on
the liquidus-solidus temperature of the brazing material and the
composition of the brazing alloy and the melting point lowering
elements. After equalising the temperature in the parts to be
brazed the temperature is raised to a brazing temperature. Both
brazing time and brazing temperature depend on the brazing material
but also on the size and shape of the article to be brazed. The
brazing may be divided into A) melting the brazing material, B)
flowing the brazing material by capillary force between adjacent
surfaces and setting the melted brazing material, and C) diffusing
the elements of the brazing material with the base material or
alloy of the parts to be brazed.
[0030] During the brazing process, the brazing material diffuses
with the adjacent surfaces so that they and the brazing material
together constitute a partly homogeneous material region.
[0031] If the temperature in the middle of the article is not high
enough the middle portion will not be brazed because the brazing
material will not melt, and the properties of the article will be
inferior.
[0032] Examples of brazing times and temperature are: heating to at
least 1100.degree. C. and heating for at least 15 minutes according
to one alternative aspect of the invention. Heating to at least
1100.degree. C. and heating for at least 30 minutes according to
another alternative aspect of the invention. Heating to at least
1100.degree. C. and heating for at least 45 minutes according to
yet another alternative of the invention. According to yet another
alternative is the article heated for more than 60 minutes.
According to a further alternative may the temperature be at least
1150.degree. C. and the time may be at least 25 minutes
[0033] A large heat exchanger may have several plates stacked
together. The plate pack may comprise 10, 20, or more plates. A
heat exchangers may have 100, 150, 200 or more plates. A large heat
exchanger may be defined by the area of the heat exchanger plated
another way of defining a big heat exchanger is the number of
plates.
[0034] During the brazing process, the brazing material diffuses
with the adjacent surfaces so that they and the brazing material
together constitute a partly homogeneous material region.
[0035] To braze together planar surfaces and form tight joints may
be hard to achieve by conventional methods. The present invention
provides a method for brazing together two planar surfaces by using
an iron-based brazing material containing melting point reducer in
such a way that the brazing material's capillary-induced
positioning between the surfaces can be controlled. The iron based
brazing filler material may be applied to planar surfaces or to
large surfaces by the aid of capillary force breakers. The
capillary force breakers can be in form of grooves, traces, paths,
passages, v or u shaped tracks or pathways etc. or in form of nets
etc. The iron-based brazing filler material may be applied into the
capillary force breakers, i.e. into the grooves, traces, paths,
passages, v or u shaped tracks, pathways, nets etc., or may the
brazing filler material be applied close to the capillary force
breakers. During heating the applied iron-based brazing filler
material will flow to the area where the capillary force may be
broken and braze together the surfaces, which are adjacent to each
other. Thus, the brazed area provides brazed, sealed or tight
cervices, joints etc. between planar surface where it is hard
otherwise to braze uniformly. The capillary force breakers enable
also brazing of surfaces having large crevices, parts having odd
shape, etc.
[0036] When the brazing material is applied between two parts close
to a capillary force breaker the flowing viscous brazing material
will stop the flowing motion and set at the rim of the capillary
force breaker. A reactor channel may be functioning as a capillary
force breaker. A plate having a reactor channel is applied with
brazing material and a barrier plate or the like is placed in
contact with the reactor channel plate. The flowing brazing
material will stop and set at boarder of the reactor channel, which
will seal the reactor plate against the barrier plate without
filling the reactor channel with set brazing material.
[0037] How far the brazing material can flow between two bordering
surfaces depends partly on the brazing materials setting time and
the distance between the surfaces, and the amount of brazing
material. Since the brazing material "sticks" to each surface,
which is to be brazed, the intermediate space between the surfaces
becomes smaller. As the intermediate space becomes smaller while at
the same time the brazing material sets, it also becomes more
difficult for the brazing material to flow in between.
[0038] The method may further comprise that in step (iii) the
brazing may take place in presence of inert gas or active shielding
gas. The heating or brazing may be carried out in presence of one
or more of the gases selected from the group consisting of helium,
argon, nitrogen, hydrogen, carbon dioxide, or one or more of the
mentioned gases in combinations with vacuum.
[0039] According to yet another aspect of the present method may
brazing zones or brazing areas, such as for example brazed joints,
pores, cracks, gaps, crevices, and the like may be provided having
an average hardness of less than 600 HV1. According to a further
alternative aspect of the present method brazing zones or brazing
areas may be provided that have an average hardness of less than
500 HV1. According to a further alternative aspect of the present
method brazing zones or brazing areas may be provided that have an
average hardness of less than 400 HV1. According to a further
alternative aspect of the present method brazing zones or brazing
areas may be provided that have an average hardness of less than
350 HV1. According to a further alternative aspect of the present
method brazing zones or brazing areas may be provided that have an
average hardness of less than 300 HV1.
[0040] Since the iron-based brazing filler materials have flow
properties and wetting properties to allow for penetration into
crevices, the iron-based brazing filler materials will create a
bond with the base material, seal crevices, and be able to join
planar surfaces by brazing. According to one alternative aspect of
the invention the iron-based brazing filler materials can seal or
fill pores, cracks, gaps, joints, or crevices larger than as large
as 1000 .mu.m, and may seal or fill pores, cracks, gaps, joints, or
crevices up to 3000 .mu.m or more. According to another alternative
aspect of the method pores, cracks, gaps, joints, or crevices
larger than 250 .mu.m may be sealed or filled by the iron-based
brazing filler material and the provided brazed zone or brazed area
having average hardness of less than 350 HV1. According to another
alternative aspect of the method pores, cracks, gaps, joints, or
crevices larger than 1000 .mu.m may be sealed or filled by the
iron-based brazing filler material and the provided brazed zone or
brazed area can have an average hardness of less than 350 HV1.
[0041] According to another alternative aspect of the method step
(iv) can comprise sealing or filling of pores, cracks, gaps,
joints, or crevices larger than larger than 300 .mu.m, or
combinations thereof, and provide brazed areas having an average
hardness of less than 350 HV1 measured at a centre line or close to
a centre line of the brazed area of filled crevices larger than 250
.mu.m.
[0042] According to a further alternative aspect of the method step
(iv) can comprise the sealing or filling of pores, cracks, gaps,
joints, or crevices larger than larger than 350 .mu.m, or
combinations thereof, and provide brazed areas having an average
hardness of less than 350 HV1 measured at a centre line or close to
a centre line of the brazed area of filled crevices larger than 300
.mu.m.
[0043] According to another alternative aspect of the method step
(iv) may comprise the sealing or filling of pores, cracks, gaps,
joints, or crevices larger than larger than 500 .mu.m, or
combinations thereof, and provide brazed areas having an average
hardness of less than 390 HV1 measured at a centre line or close to
a centre line of the brazed area of filled crevices larger than 400
.mu.m.
[0044] The desired amount of brazing material is supplied to the
contact points, which are to be brazed together in any of the
described or other ways. The brazing material can cover an area
that is somewhat larger than the contact joint point. The contact
joint points may have a diameter of at least 0.5 mm.
[0045] According to the present method any suitable iron-based
brazing filler material may be used. Suitable iron-based brazing
filler materials may be selected from the material disclosed in WO
02/38327, WO 02/098600, U.S. Pat. No. 3,736,128, U.S. Pat. No.
4,402,742, U.S. Pat. No. 4,410,604, U.S. Pat. No. 4,516,716, U.S.
Pat. No. 6,656,292, or EP 0 418 606. According to one alternative
aspect of the present method the iron-based brazing filler
materials may be selected from the material disclosed in WO
02/38327 or in WO 02/098600. According to another alternative
aspect of the present method the iron-based brazing filler
materials may comprise one or more of Si, B, P, Mn, C, or Hf.
According to yet another alternative aspect of the present method
the iron-based brazing filler material may comprise 9-30 wt % Cr,
5-25 wt % Ni, and at least one of 0-25 wt % Si, 0-6 wt % B, 0-15 wt
% P, 0-8 wt %, Mn, 0-2 wt % C, 0-15 wt % Hf, and as an alternative
balanced with other elements. According to another alternative
aspect of the present method the iron-based brazing filler material
may comprise at least 40 wt % Fe, 14-21 wt % Cr, 5-21 wt % Ni, 6-15
wt % Si, 0.2-1.5 wt % B, and as an alternative balanced with other
elements. According to another alternative aspect of the present
method the iron-based brazing filler material may comprise at least
40 wt % Fe, 14-21 wt % Cr, 5-21 wt % Ni, 4-9 wt % Si, 4-9 wt % P,
and as an alternative be balanced with other elements. According to
another alternative aspect of the present method the iron-based
brazing filler material may comprise at least 40 wt % Fe, 14-21 wt
% Cr, 5-21 wt % Ni, 7-15 wt % P, and as an alternative be balanced
with other elements.
[0046] Since the brazing process is a metallic process and the
respective surfaces for brazing take the form of metallic material,
then iron-based brazing material during the brazing process
diffuses with bordering surfaces, which are to be brazed together.
The joint or seam between the two joined surfaces will more or less
"disappear" during the brazing process according to one aspect of
the invention. The brazed seam together with the surfaces of the
metallic parts will become a unity with only small changes in
material composition of the alloys.
[0047] The present invention also relates to an article of
stainless steel obtained by employing the present method. The
present invention relates further to a brazed article of stainless
steel, which comprises at least one base material of stainless
steel and a brazing filler material wherein the obtained brazed
areas, pores, cracks, gaps, joints, or crevices have a tensile
strength of at least about 110 N/mm.sup.2. According to one
alternative aspect the brazed areas, pores, cracks, gaps, joints,
or crevices can have a tensile strength of at least about 120
N/mm.sup.2.
[0048] The present invention also relates to a brazed article of
stainless steel, which comprises at least one base material of
stainless steel and a iron-based brazing filler material, wherein
the obtained brazed areas, pores, cracks, gaps, joints, or crevices
have an average hardness of less than about 600 HV1. According to
one alternative aspect the brazed article of stainless steel may
comprise at least one base material of stainless steel and an
iron-based brazing filler material wherein the obtained brazed
areas, pores, cracks, gaps, joints, or crevices having an average
hardness less than about 500 HV1. According to another alternative
aspect may the brazed article of stainless steel may comprise at
least one base material of stainless steel and an iron-based
brazing filler material wherein the obtained brazed areas, pores,
cracks, gaps, joints, or crevices have an average hardness of less
than about 450 HV1. According to yet another alternative aspect the
brazed article of stainless steel may comprise at least one base
material of stainless steel and an iron-based brazing filler
material wherein the obtained brazed areas, pores, cracks, gaps,
joints, or crevices have an average hardness less than 350 HV1. The
"at least one base material of stainless steel" according to one
alternative of the invention one base material can be stainless
steel brazed together by the iron-based brazing filler material.
The "at least one base material of stainless steel" according to
another alternative of the invention one base material can be
stainless steel and another base material of another metal alloy
brazed together by the iron-based brazing filler material.
[0049] According to one alternative aspect the articles or the
parts may be selected from reactors, separators, columns, heat
exchangers, or equipments for chemical plants or food plants, or
for car industry. According to another alternative aspect the
objects may be heat exchangers, plate reactors, or combinations
thereof.
[0050] According to another alternative aspect of the invention the
brazed article may be a paring disc, which is used in a
separator.
[0051] According to one alternative aspect the articles maybe
brazed heat exchanger plates, brazed reactor plates, or
combinations thereof having a burst pressure of at least about 60
Bar. According to another alternative aspect the articles maybe
brazed heat exchanger plates, brazed reactor plates, or
combinations thereof having a burst pressure of at least about 65
Bar. According to another alternative aspect the articlesmay be
brazed heat exchanger plates, brazed reactor plates, or
combinations thereof having a burst pressure of at least about 80
Bar. According to yet another alternative aspect the articles maybe
a heat exchanger having a heat exchanger plate area larger than
about 0.20 m.sup.2, a burst pressure of at least 65 Bar, and a
porthole area of larger than about 0.003 m.sup.2.
[0052] When the parts are heat exchanger plates, the plates can be
endplates, adaptor plates, sealing plates, frame plates etc., and
constitute a heat exchanger system. Each of the heat exchanger
plates comprise at least one port recess, which port recesses
together form part of a port channel when the plates are placed on
one another. The plates are stacked together in a plate stack or a
plate pack in the heat exchanger. The plate package comprises
between the plates a number of channels, which accommodate a number
of media. The media in adjacent channels is subject to temperature
transfer through the heat transfer plate in a conventional manner.
The plates may comprise an edge, which may partly extend down and
over the edge portion of an adjacent heat transfer plate in the
plate stack. The edges of the plates seal against the adjacent heat
transfer plate in such a way that a channel may be formed between
the plates. This channel either allows flow of a medium or is
closed so that no flow takes place and the channel is therefore
empty. To stiffen the plate package and the port regions, an
adaptor plate or an endplate may be fitted to the package. The
surfaces of the endplate or the adaptor plate are substantially
planar so that contact surfaces between the surfaces may be
maximised. As previously mentioned, the respective port recesses on
the plates coincide, thereby forming a channel. On the inside of
this port channel there is therefore a joint between the two
plates. To prevent leakage at this joint brazing material may be
applied around the port region between the plates. The brazing
material may be placed in or close to a capillary force breaker,
which may extend wholly or partly around the port region between
the plates. In the plate package brazing material may be applied on
different pre-designed or predetermined parts of the plates. During
the brazing process, the brazing material will become viscous and
will flow from the applied parts out between the plates due to the
action of capillary force. The advantage of applying brazing
material onto predetermined places makes it possible to control the
volume and amount of the brazing material, and to control which
parts of the surfaces are to be brazed and which are not. When
brazing a heat exchanger at least three heat exchanger plates are
needed, but it is usual that several plates are brazed together.
According to one alternative aspect of the invention a plate pack
of several plates are brazed together at the same time in the same
oven.
[0053] The brazing method of the invention may either comprise
brazing the article assembled with all its parts at the same time
or the article may be brazed in a stepwise fashion where parts are
first assembled and brazed together, and then assembled with
further parts and brazed together, and so on using the same type of
brazing material in each brazing cycle.
[0054] According to a further alternative aspect of the invention
the articles may be provided wherein the brazed areas, pores,
cracks, gaps, joints, or crevices having a silicone content of at
least about 2 wt % Si.
[0055] Further aspects and embodiments of the invention are defined
by the sub-claims.
[0056] In the following the present invention will be explained in
more detail by means of the attached photos.
BRIEF DESCRIPTION OF THE FIGURES
[0057] FIG. 1 is a photo showing a cross section of a part of a
heat exchanger.
[0058] FIG. 2 is a schematic drawing showing a cross section of a
joint.
[0059] FIG. 3 is a photo showing a cross section of a joint on
which hardness tests are carried out.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0060] As shown in FIG. 1, an iron-based brazing filler material is
able to fill large cervices, and that it is possible to braze with
large quantities of brazing material. The large heat exchangers
braze joints contain a lot of braze filler applied and also that
large homogenisation zones are found. A part of the braze filler
and part of the original plate thickness have been mixed into the
homogenisation zone.
[0061] FIG. 2 is schematically shows relationships between
different parameters in a brazed crevice or joint, brazed by filler
material F. Letter A represents the plate thickness of plate E
which also represents base material E. The letter B represents the
smallest thickness of a brazed crevice or joint between base
material E or plates E. The letter C represents the largest
thickness of a brazed crevice or joint without any pores, cracks or
passages, and letter D represents the largest thickness of a brazed
crevice or joint where any pores, cracks or passages G opens up to
but is still sealed. If there is no trace of any pores, cracks or
passages then C=D. For nickel based filler material C=D is less
than C=D for iron based filler material. The presences of pores,
cracks or passages make the brazed zone less strong.
[0062] FIG. 3 is a photo showing a cross section of a joint on
which hardness tests have been carried out. The average hardness is
calculated as a numeric average and depends on the number of
tests.
[0063] The invention will be further illustrated in the Examples,
which are for the purpose of clarifying the invention and not to
limit its scope. If not otherwise stated in the examples and tables
percentages are given by weight (wt %).
Example 1
[0064] Test samples having geometry similar to the plate pattern
inside brazed thin walled pressed heat exchanger plates were
tested. The applied amount of braze-filler material was
approximately 16 to 20 g per 4 brazing points. A nickel based braze
filler BNi-5 according to AWS A5.8 AMS specifications for
braze-fillers was compared to an iron-based braze-filler comprising
56 wt % Fe, 17 wt % Cr, 12 wt % Ni, 12 wt % Si, and 1 wt % B. The
braze filler was applied to the test samples having 0.3-0.4 mm
crevices, and the samples were heated in a furnace to a temperature
of about 1200.degree. C. in a non-oxidative atmosphere. The test
results are summarised in Table 1.
TABLE-US-00001 TABLE 1 Ni-based Sample BNi-5 Iron-based [g]
[N/mm.sup.2] [N/mm.sup.2] 16 109 123 18 110 126 20 106 151
The test results show that the Fe-based braze-filler, can fill
crevices that are large see FIG. 1, and can obtain very good
strength at the same time compared to Ni-based braze-fillers. Even
at the test amount, it can be seen that the Fe-braze has the best
mechanical strength of the tested fillers. FIG. 1 shows a
cross-section of a Fe-based brazed heat exchanger. In the picture,
it can be seen that crevices between 0.4-0.6 mm are tightened.
Example 2
[0065] Now it has been found that the iron based braze-filler not
only has the capability of filling large crevices but also has a
very high mechanical strength at large crevices, making them
suitable for brazing for example large heat exchangers or planar
surfaces of for example reactor plates. Tests were performed by
comparing the amount of braze filler to tensile strength, the
results are summarised in Table 2.
TABLE-US-00002 TABLE 2 Iron based Sample (invention) [g]
[N/mm.sup.2] 25 162 55 227
Example 3
[0066] A series of tests were performed by changing the heat
treatment cycle of the brazening process to obtain as good a
filling as was possible. A significant difference was discovered,
even at a very short heat treatment cycle (5 minutes), very good
filling was obtained with the Fe-based filler. The brazing tests
were carried out at 1100.degree. C. comparing the ability to fill
crevices between a nickel based filler (BNi-5) and an iron based
filler comprising 56 wt % Fe, 17 wt % Cr, 12 wt % Ni, 12 wt % Si,
and 1 wt % B. The results are summarized in Table 3.
TABLE-US-00003 TABLE 3 C FIG. 2 C FIG. 2 Time BNi-5 iron-based
filler [minutes] [.mu.m] [.mu.m] 5 130 800-1200 15 180 800-1200 30
220 800-1200 150 300 800-1200
The test results show that BNi-5 needs a long heat treatment to
braze larger joints, but even after long heat treatment times BNi-5
did not fill crevices as good as the iron-based filler. The
iron-based filler filled larger crevices in very short time
compared to BNi-5. The longer brazing times for BNi-5 are therefore
more energy consuming than those for the iron based filler.
Example 4
[0067] The hardness tests were made in a joint at an equally sealed
gap between two plates of base material (type 316). The tests were
performed on an equal distance from the base material, in the
centre of the joint. Hardness measurements HV1 were performed
according to ASTM E92-82 (Standard test method for Vickers Hardness
of Metallic Materials) and EN ISO 6507-1 (Metallic
materials--Vickers hardness test--Part 1: Test method (ISO
6507-1:1997), and a comparison was made between a joint of BNi-5
and a joint of Fe-based material 56 wt % Fe, 17 wt % Cr, 12 wt %
Ni, 12 wt % Si, and 1 wt % B. The results are summarised in Table
4.
TABLE-US-00004 TABLE 4 Joint made with Joint made with BNi-5
Fe-based material [HV1] [HV1] 490 260 600 210 520 280 480 270
The hardness test results show that BNi-5 joint is harder than the
Fe-based material joint. Thus, the BNi-5 joint shows less ductility
and consequently lower strength than the iron-based filler joint
according to the invention, which is illustrated by lower hardness
values of the iron-based filler joint. Thus, the BNi-5 joint is
brittle compared to the iron-based filler joint.
Example 5
[0068] Hardness tests were preformed on a large joint sealed with
Fe-based filler comprising 56 wt % Fe, 17 wt % Cr, 12 wt % Ni, 12
wt % Si, and 1 wt % B. The tests were performed where the brazed
joint has sealed a gap larger than 1000 .mu.m, and the positions
where the tests were done as in FIG. 3, but the photo in FIG. 3 is
not a photo of the joint in this Example. The results are 349 HV1,
336 HV1, 210 HV1, 197 HV1, 250 HV1, 300 HV1, and 287 HV1, which
gives average hardness of 275 HV1.
Example 6
[0069] In this example tests were carried out to produce a heat
exchanger without leakage, i.e. which is fully brazed without
defaulting joints. An iron-based filler defined in WO 02/38327 was
applied between pressed plates. For each test 20 plates were used.
The plates had an approximate dimension of: width 400 mm, length
1000 mm, and thickness 0.4 mm. The plates were placed on a fixture,
and on top of the plates was a fixture with a weight placed. The
pack of plates was heated in a vacuum furnace. Several brazing
tests were carried out with heat exchanger plate packs, and the
tests were carried out in different heat treatment cycles.
[0070] In all tests of the heat treatment cycles the heat exchange
plate pack was first heated to 500.degree. C. for 1 hour, then the
temperature was raised to 1100.degree. C. for 4 hours to ensure
heating of the whole plate pack.
[0071] Test A: The furnace was heated from 1100.degree. C. to
1200.degree. C. for 5 minutes, and then the heat was lowered to
1100.degree. C. for approximately 30 minutes.
[0072] Test B: The furnace was heated from 1100.degree. C. to
1200.degree. C. for 15 minutes, and then the heat was lowered to
1100.degree. C. for approximately 30 minutes.
[0073] Test C: The furnace was heated from 1100.degree. C. to
1200.degree. C. for 30 minutes, and then the heat was lowered to
1100.degree. C. for approximately 30 minutes.
[0074] Test D: The furnace was heated from 1100.degree. C. to
1200.degree. C. for 60 minutes, and then the heat was lowered to
1100.degree. C. for approximately 30 minutes.
[0075] Analysis: The plate packs were cut into sections to be
analysed if the iron-based filler in the centre part of the plate
pack had melted or not. The tested parts were optically
investigated.
Results:
[0076] Test A: Filler in the centre not melted. Test B: Filler in
the centre not melted. Test C: Filler in the centre partly melted
(more sintered). Test D: Filler in the centre melted.
* * * * *