CN107000056A - 预烧结钎焊 - Google Patents

预烧结钎焊 Download PDF

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CN107000056A
CN107000056A CN201580063305.XA CN201580063305A CN107000056A CN 107000056 A CN107000056 A CN 107000056A CN 201580063305 A CN201580063305 A CN 201580063305A CN 107000056 A CN107000056 A CN 107000056A
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metal
powdered
sintered
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metallurgical
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杰夫·勒希安
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Mechadyne PLC
Metaldyne LLC
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Mechadyne PLC
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24—Selection of soldering or welding materials proper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • B22F3/1017—Multiple heating or additional steps
    • B22F3/1021—Removal of binder or filler
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
    • B22F7/062—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts
    • B22F7/064—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts using an intermediate powder layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/02—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape
    • B23K35/0222—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape for use in soldering, brazing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/02—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape
    • B23K35/0222—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape for use in soldering, brazing
    • B23K35/0244—Powders, particles or spheres; Preforms made therefrom
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24—Selection of soldering or welding materials proper
    • B23K35/30—Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24—Selection of soldering or welding materials proper
    • B23K35/30—Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
    • B23K35/302—Cu as the principal constituent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24—Selection of soldering or welding materials proper
    • B23K35/30—Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
    • B23K35/3053—Fe as the principal constituent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24—Selection of soldering or welding materials proper
    • B23K35/30—Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
    • B23K35/3053—Fe as the principal constituent
    • B23K35/306—Fe as the principal constituent with C as next major constituent, e.g. cast iron
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24—Selection of soldering or welding materials proper
    • B23K35/30—Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
    • B23K35/3053—Fe as the principal constituent
    • B23K35/3066—Fe as the principal constituent with Ni as next major constituent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24—Selection of soldering or welding materials proper
    • B23K35/30—Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
    • B23K35/3053—Fe as the principal constituent
    • B23K35/3073—Fe as the principal constituent with Mn as next major constituent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24—Selection of soldering or welding materials proper
    • B23K35/30—Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
    • B23K35/3053—Fe as the principal constituent
    • B23K35/308—Fe as the principal constituent with Cr as next major constituent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24—Selection of soldering or welding materials proper
    • B23K35/30—Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
    • B23K35/3053—Fe as the principal constituent
    • B23K35/308—Fe as the principal constituent with Cr as next major constituent
    • B23K35/3086—Fe as the principal constituent with Cr as next major constituent containing Ni or Mn
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/36—Selection of non-metallic compositions, e.g. coatings, fluxes; Selection of soldering or welding materials, conjoint with selection of non-metallic compositions, both selections being of interest
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • B22F2998/10—Processes characterised by the sequence of their steps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy

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  • Powder Metallurgy (AREA)
  • Ceramic Products (AREA)

Abstract

本申请描述了通过预烧结粉末金属的冶金接合点将第一金属部件和第二金属部件相连接的制品，所述预烧结粉末金属插入在第一和第二金属部件的相邻表面之间。本申请还描述了一种用于钎焊工艺的组合物，其包含预烧结的粉末金属。本申请还描述了用于钎焊的工艺，包括以下步骤：预烧结粉末金属；将预烧结的粉末金属添加至第一和第二金属部件；加热含有预烧结粉末金属的第一和第二金属部件的组合，直到粉末金属熔化并将金属部件连接形成冶金接合点。

Description

预烧结钎焊
相关申请的交叉引用
本申请要求于2014年11月21日提交的题目为“预烧结钎焊”的美国临时申请号62/082,736的优先权，该申请的全部内容在此通过引用并入本文。
技术领域
本发明涉及一种通过钎焊连接部件(components)的方法，并且更具体地涉及用于在H2-N2气氛中钎焊粉末金属的改进的方法和装置。。
背景技术
通常在特定的气氛中对粉末金属部件进行钎焊。钎焊可能在烧结过程中或者之后发生。钎焊需要非常高的温度，这可能导致不希望的金属氧化。为了避免这种氧化，可能需要使用非空气的气氛。
通常钎焊气氛需要的还原电位比标准的H2-N2气氛可达到的还原电位更强。通常，这可以通过使用吸热气体、甲烷或CO/CO2或系统内定量加料(dosing)来实现。然而，这些方法具有缺点。
增加额外步骤和组合物使钎焊工艺复杂化，并产生附加失误几率。此外，增加的部件使制造成本及废物和废料增加。因此，需要一种改进的系统和方法。
发明内容
本申请描述了通过预烧结粉末金属的冶金接合点(joint)将第一金属部件和第二金属部件相连接的制品，其中所述预烧结粉末金属插入在第一金属部件和第二金属部件的相邻表面之间。粉末金属可以选自铁、碳、铜、镍、钼、铬、锰或其两种或更多种的组合。此外，也可以通过铜渗透工艺制造粉末金属。
可以在由空气、氢气、氮气、氦气、甲烷、吸热气体(endogas)或其中两种或更多种的组合组成的气氛下对粉末金属进行预烧结。另外，粉末金属可以在约300℉-1500℉的温度下预烧结。在一个实施方案中，粉末金属不含润滑剂。在一个实施方案中，粉末金属不含助熔剂。
在一个实施方案中，制品的冶金接合点通过钎焊工艺形成。钎焊工艺可能在H2-N2气氛中进行。
冶金接合点的断裂强度至少为35000kN，至少为45000kN，或甚至至少为55000kN。
本申请还描述了一种用于焊接工艺的组合物，所述组合物包含预烧结的金属粉末。本申请还描述了一种钎焊工艺，包括以下步骤：预烧结粉末金属；添加预烧结的粉末金属到第一和第二金属部件中；和加热含有预烧结粉末金属的第一和第二金属部件的组合，直到所述粉末金属熔化并连接所述金属部件以形成冶金接合点。
附图说明
通过参考结合以下图表的详细描述，可以更好地理解该技术的操作，其中：
图1说明了钎焊前后的金属部件和钎焊颗粒(pellets)；
图2A-2D是示出所述球已经熔化和与被连接的金属部件合金化后金属部件内的钎焊颗粒不同放大图；
图3A-3B示出各种扭矩试验夹具；
图4A-4D示出各种拉伸试验夹具。
具体实施方式
现在将详细列出本申请的示例性实施方案，其示例在附图中示出。应当理解，在不脱离本申请的相应范围的情况下可以使用其他实施方案并且可以进行结构和功能的改变。此外，在不脱离本申请范围的情况下，可以组合或改变各种装置的特征。因此，以下描述仅以说明的方式给出，并且，不以任何方式限制可对示出的实施方案进行的且仍然在本申请的精神和范围内的各种改变和修改。
通常呈现预烧结钎焊的方法。与目前已知和使用的方法不同，预烧结钎焊这种方法减少了钎焊过程中将使用的额外的步骤和添加剂的需求。典型的钎焊工艺需要通过定量加入吸热气体、甲烷等添加剂来改变常规的H2-N2气氛。
通过使用填料金属作为介质，钎焊工艺通常用于连接金属部件。所述填料被加热到其熔点以上并分布在金属部件之间。
通常，在钎焊工艺中用钎焊颗粒作连接介质。钎焊颗粒可以由任何合适的材料形成，例如被压制成颗粒形式的粉末金属。合适的粉末金属的包括但不限于黄铜，青铜，铜、锡、锰、硅和其他常见金属组合的合金。钎焊颗粒还可能包含添加剂，例如模润滑剂和助熔剂。润滑剂和助熔剂可以包含在粉末金属中并形成颗粒。合适的润滑剂和助熔剂的包括但不限于硼砂、氯化物、氟化物、磷酸盐、蜡、硬脂酸盐和金属硬脂酸盐。
图1展示了在钎焊工艺中使用的部件。图中显示出了第一金属部件、支架(spider)10，和第二金属部件、法兰12。支架(10)和法兰(12)可以由任何适当的金属形成，包括但不限于钢和其它合金。支架10可包括固定到通常平面基底16的一个或多个臂14。基底16可以是通常如图1所示的圆形(circular)，或者可以是任何其它合适的形状，包括但不限于正方形、矩形、卵形、五边形、六边形等。目前的教导不局限在此描述的形状。可以使用任何形状的基底16。在一些实施方案中，支架10的平面基底16可以具有中心孔18和从平面基底16向外延伸的一个或多个臂14。臂14可以是任何适当的形状，包括但不限于圆形(round)、长方体、圆柱形、圆形(circular)等。此外，臂14可以最终是任何期望的形状，包括但不限于放大的裂片(lobes)、钝端，锥形端，圆形远端，T形远端，Y形远端等。支架10中的臂14的数量可以改变，例如一到六个或更多。臂14可以围绕平面基底16的边缘均匀地间隔开，或者在不同臂14间可以改变距离。臂14之间的间隙可以允许流体和固体材料的移动。
法兰12可以是如图1所示的圆形，或者可以是任何其它合适的形状，包括但不限于正方形、矩形、卵形、五边形、六边形等。本教导不受形状的限制，可以使用任何适当的形状。法兰12可以具有顶侧20和下侧(未示出)。法兰12可具有通常的凸形、通常的平面形状或者通常的凹形，并且可以配置成在底部接收和/或接触支架10的臂14。法兰12可包括中心孔22和开口24，其被设计用于在中心孔22周围的顶侧20接收颗粒26。
支架10和法兰12可以组合以形成用于自动变速器的承载部件28。在一个实施方案中，法兰12可以放置在支架10的顶部，使得支架10的臂14与法兰12的开口24匹配。这种配置将允许钎焊颗粒26接触支架10和法兰12。虽然在本申请中讨论了支架10和法兰12，应理解，本文所述的钎焊工艺可以使用和应用于任何类型的金属部件。
图1进一步说明了钎焊颗粒26。钎焊颗粒26可以由金属粉末、润滑剂和助熔剂组成。合适的金属粉末和合金的实例包括但不限于铁、碳、铜、镍、钼、铬、锰、硅、硼及其两种或多种的组合。在一个实施方案中，颗粒26可包括使用铜渗透方法构造的合金。合适的润滑剂和助熔剂的实例包括但不限于硼砂、氯化物、氟化物、磷酸盐、酰胺蜡或金属硬脂酸盐。在一些实施方案中，颗粒26不含有任何润滑剂。在一些实施方案中，颗粒26不含有任何助熔剂。在一些实施方案中，颗粒26既不含有任何润滑剂或助熔剂。
钎焊颗粒16可以形成为任何合适的颗粒形状和尺寸，包括但不限于圆形(circular)、长方体、圆柱体等。钎焊颗粒26可以形成为任何合适尺寸的颗粒，包括但不限于平面尺寸为3-10mm或直径为0-10mm。钎焊颗粒26可以选自任何市售的钎焊粉末或预成型钎焊合金制品，其包括压制润滑剂，例如酰胺蜡、金属硬脂酸盐和其它专用的润滑剂和助熔剂。这些市售的钎焊粉末和预成形钎焊合金制品包括来自Hoeganaes公司的ANCORBRAZE72。
该工艺过程的第一步骤，即预烧结步骤中，可以对钎焊颗粒26进行热处理以除去钎焊合金中的润滑剂。这可以通过将颗粒26特定加热至熔化或从颗粒26中蒸发润滑剂材料所需的温度来实现。在一个实施方案中，所需温度可以为约300℉-1500℉、约400℉-1400℉、约500℉-1300℉、约600℉-1200℉、约700℉-1100℉、约800℉-1000℉，甚至约850℉-950℉。在一个实施方案中，热处理温度可以在约1200℉-1900℉之间。然而，应理解，从颗粒18的钎焊合金中除去润滑材料所需的任何适当的温度均可使用。
预烧结工艺可以在炉、烘箱、实验室或任何其它合适的环境中进行。预烧结环境可以包括任何合适的气氛，包括但不限于空气、氢气、氮气、氦气、甲烷、吸热气体，或其两种或更多种的组合。
一旦润滑材料已从颗粒18的钎焊合金中移除，钎焊颗粒26可以用于钎焊过程中。对于钎焊工艺中的第一步骤，法兰12可以放置在支架10的顶部，使得支架10的臂14与法兰12的开口24匹配。如图1所示，颗粒26可以放置在法兰12的开口17内。开口17可以特别地设计成使颗粒和钎焊合金与支架10和法兰12接触。
一旦钎焊颗粒26已被定在合适的开口17中，可以将金属部件放置到炉中。因为钎焊需要异常高的温度，这可能引起氧化，炉可以用除空气之外的气氛。例如，为了避免氧化，所述炉可以使用H2-N2、He或Ar气氛的组合。
与现有的受益于使用吸热气体，例如甲烷或CO/CO2或系统内定量加料的钎焊工艺不同，这些附加物是不必要的。所述炉可以使用H2-N2气氛，而无任何吸热气体添加剂或甲烷加入。钎焊颗粒预热处理后，无任何添加的吸热气体或甲烷加入，H2-N2气氛就足以提供可接受的润湿性和钎焊界面强度。
在加热支架10和法兰12后，颗粒26可熔化并与支架10和法兰12的金属合金化，从而在支架10和法兰12之间形成钎焊接合点30。在图2A中显示出最终的钎焊部分30。图2B显示出了钎焊接合点30的7倍的放大图。图2C显示出了钎焊接合点30的10倍的放大图。图2D显示出了钎焊接合点30的50倍的放大图。
与不使用预烧结钎焊颗粒的钎焊接合点相比，此钎焊接合点的可具有提高的强度。如下表1所示，“绿色球粒”(“Green Pill”)(即用非预烧结颗粒制成的钎焊接合点)的断裂平均值，比用预烧结颗粒制成的钎焊接合点断裂平均值(kN)低。断裂强度是以通过一种基底金属的断裂或通过钎焊接合点本身的断裂形成组件分离的形式而产生的张力。这种测试可以通过纯拉伸试验进行，或者可以通过扭矩试验进行，如图3A-3B和4A-4D所示。
表1.预烧结和非预烧结钎焊接合点的断裂平均值
样品B、C和D在空气中去润滑剂(delubed)，并在H2-N2中钎焊。样品E在氮气中去润滑剂并在H2-N2中钎焊。使用预烧结样品(样品B、C和D)的冶金接合点的平均具有57761kN的断裂平均值，相比较于对照的断裂平均值29421kN，近似两倍。因此，预烧结钎焊颗粒26增加了钎焊制品的平均断裂并因此增加了强度。在一个实施方案中，使用预烧结样品的冶金接合点的平均断裂强度可大于35000kN。在一个实施方案中，使用预烧结样品的冶金接合点的平均断裂强度可以大于45000kN。在一个实施方案中，使用预烧结样品的冶金接合点的平均断裂强度可以大于55000kN。在一个实施方案中，使用预烧结样品的冶金接合点的平均断裂强度可以大于60000kN。
虽然上面的示例是对于法兰和支架，它们被配置以连接在一起以形成承载部件，但是本技术可以用于任何适当的部件。例如，该技术在可用于汽车行业中以形成当面对高应力情况时需要是强壮的部件。在一个实施方案中，该技术可以用于发动机部件或传动部件。该技术还可以用于汽车行业以外的其他领域，例如航空航天、制造业，建筑等。
虽然本申请的实施方案已经在附图中示出并且在前面的详细描述中进行了描述，但是应当理解，本申请不局限于所公开的实施方案，而是可以在不脱离申请权利的要求的范围情况下进行多种重新设计、改进和替换。以下权利要求书旨在包括所有的修改和替换，只要它们落入权利要求及其等价物的范围内。

Claims (23)

1.一种制品，其包含通过预烧结粉末金属的冶金接合点连接至第二金属部件的的第一金属部件，所述预烧结粉末金属插入在第一金属部件和第二金属部件的相邻表面之间。
2.根据权利要求1所述的制品，其中所述粉末金属选自铁、碳、铜、镍、钼、铬、锰或其两种或更多种的组合。
3.根据权利要求2所述的制品，其中所述粉末金属通过铜渗透工艺制造。
4.根据权利要求2所述的制品，其中所述粉末金属是在选自空气、氢气、氮气、氦气、甲烷、吸热气体或其两种或更多种的组合的气氛中预烧结的。
5.根据权利要求4所述的制品，其中所述粉末金属在约300℉-1500℉的温度下预烧结。
6.根据权利要求5所述的制品，其中所述粉末金属不含有润滑剂。
7.根据权利要求6所述的制品，其中所述粉末金属不含有助熔剂。
8.根据权利要求7所述的制品，其中所述冶金接合点通过钎焊工艺形成。
9.根据权利要求8所述的制品，其中钎焊工艺在H2-N2气氛中进行。
10.根据权利要求9所述的制品，其中所述冶金接合点的断裂强度为至少35000kN。
11.根据权利要求9所述的制品，其中所述冶金接合点的断裂强度为至少45000kN。
12.根据权利要求9所述的制品，其中所述冶金接合点的断裂强度为至少55000kN。
13.一种用于钎焊工艺中的组合物，其包括预烧结的粉末金属。
14.根据权利要求13所述的组合物，其中所述预烧结的粉末金属选自铁、碳、铜、镍、钼、铬、锰或其两种或更多种的组合。
15.根据权利要求14所述的组合物，其中所述粉末金属通过铜渗透工艺制造。
16.根据权利要求15所述的组合物，其中所述粉末金属在选自空气、氢气、氮气、氦气、甲烷、吸热气体或其两种或更多种的组合的气氛中预烧结。
17.根据权利要求16所述的组合物，其中所述粉末金属在约300℉-1500℉的温度下预烧结。
18.根据权利要求17所述的组合物，其中所述粉末金属包含酰胺蜡、金属硬脂酸盐、润滑剂和助熔剂。
19.根据权利要求18所述的组合物，其中通过预烧结除去所述润滑剂。
20.根据权利要求19所述的组合物，其中通过预烧结除去所述助熔剂。
21.根据权利要求20所述的组合物，其中所述粉末金属在300℉-1500℉的温度下预烧结。
22.根据权利要求21所述的组合物，其中所述粉末金属在选自空气、氢气、氮气、氦气、甲烷、吸热气体或其两种或更多种的组合的气氛中预烧结。
23.钎焊方法，其包括：
预烧结粉末金属；
将预烧结的粉末金属添加至第一和第二金属部件；
加热含有预烧结粉末金属的第一和第二金属部件的组合，直到粉末金属熔化并连接金属部件以形成冶金接合点。
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