US2332330A - Method for joining aluminum structures - Google Patents

Method for joining aluminum structures Download PDF

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Publication number
US2332330A
US2332330A US422997A US42299741A US2332330A US 2332330 A US2332330 A US 2332330A US 422997 A US422997 A US 422997A US 42299741 A US42299741 A US 42299741A US 2332330 A US2332330 A US 2332330A
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United States
Prior art keywords
aluminum
blade
metal
structures
joining
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Expired - Lifetime
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US422997A
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Kenton D Mcmahan
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General Electric Co
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General Electric Co
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Priority to US422997A priority Critical patent/US2332330A/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D21/00—Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
    • B22D21/002—Castings of light metals
    • B22D21/007—Castings of light metals with low melting point, e.g. Al 659 degrees C, Mg 650 degrees C
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • B22D19/04—Casting in, on, or around objects which form part of the product for joining parts
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49316—Impeller making
    • Y10T29/4932—Turbomachine making
    • Y10T29/49321—Assembling individual fluid flow interacting members, e.g., blades, vanes, buckets, on rotary support member

Definitions

  • the present invention relates to a method for joining metals having substantially the same aluminum is cast around a solid aluminum structure an oxide film on the solid aluminum prevents fusion of the cast and solid metal. If a flux is employed in such a process, for example in joining an aluminum fan blade to a supporting aluminum structure by casting the supporting structure about the fan blade, there is a tendency to form a bond at the extreme end of the blade but the flux is merely added to the oxide layer on the blade and prevents fusion between the molten and the solid metal,
  • One of the objects of the present invention is to provide an eicient and reliable method for obtaining strong. sound junctions between metal structures having substantially equal melting points and particularly between aluminum or aluminum alloy structures. appear hereinafter.
  • Fig. 1 is a cross sectional view of an aluminum fan blade positioned in a sand mold and embodying the features of my invention
  • Fig. 2 is a cross sectional view of the same blade after molten aluminum has been poured into the mold
  • Fig. 3 is a cross sectional View of a modified form of my invention
  • Fig. 4 is a view partly in elevation and partly in cross section of the fan blade and mold shown in Fig. 3
  • Fig. 5 is a fan constructed in accordance with my invention.
  • a structure which may be an aluminum fan blade I is positioned in a sand mold 2.
  • the blade I may be supported at opposite ends thereof Further objects will ⁇ as indicated in Fig. 5 of the drawing.
  • the extreme outer end of the blade II is provided with a somewhat bulbous portion 3 which is shown as triangular in shape in Fig. 1 but may be any desired form.
  • the part 3 is joined to the blade proper by means of a reduced, very thin section or junction 4. If desired. a small amount of flux 5 may be applied to the lower surface of the part 3, as indicated in Fig. 1, to facilitate transfer of heat from the molten metal into that part.
  • the problem of making the blade I fuse into a molten mass of aluminum is primarily one of heat transfer across an oxide layer and of heat conduction away from the junction 4 and through the blade I.
  • a blade which has a bulbous or dovetailed outer end portion 3 connected to the main body of the blade by a very narrow or thin section of metal asindicated in Fig. 1, the greatly reduced volume of metal in the narrow section substantially isolates the enlarged portion 3 from the main body of blade I with respect to thermal conductivity.
  • This effect in combination with the ilux coated portion of the part 3 results in complete melting of that part when molten aluminum 6 is poured into the sand mold 2 and around the portion 3 of the blade.
  • the oxide coating on the blade proper is thereby broken and the line of contact between the blade and molten metal widens tothe full thickness of the blade, as indicated by the shaded portion of Fig. 2 with the result that the end portion of the blade fuses into the molten metal and sets with it thereby forming a strong, durable bond.
  • the oxide layer on the aluminum is pushed to the outer surface of the cast aluminum as indicated at 1 in Fig. 2 of the drawing. At this point the oxide layer is without harmful effect.
  • any ilux 8 which has been applied to the outer surfaces will float to the outer surface of the cast aluminum as indicated in Fig. 2 and may be removed by a cleaning or machining operation.
  • the fan blade I is shown as having a somewhat enlarged portion 9 adjacent its outer end provided with opposite parallel grooves I0 and II. It is unnecessary, however, to employ either grooves or an enlarged section.
  • a substantially flat blade I2 The outer or lower end of this blade is provided with a yseries of closely adjacent punched-out portions I3 which give the eiect of a thin necked down or dovetailed section.
  • the thin sections Il act in substantially the same manner as the reduced section 4 shown in Fig. 1.
  • aluminum as employed in the present specification and claims is intended to include aluminum base alloys as well as aluminum. Furthermore, while the present method is illustrated in connection with aluminum or aluminum alloys it may be employed in joining other metals. The metals to be joined, however, should have substantially the same melting point.
  • the method of joining two aluminum struc- 'A tures which comprises providing a bulbous portion connected to the main body portion through a reduced section of metal to thereby substantially thermally isolate said bulbous portion from the main body portion of said structure. positioning said aluminum structure in a mold and pouring molten aluminum around said reduced section and bulbous portion.
  • the method of joining two metal structures having substantially equal melting points which comprises providing one of said structures with an auxiliary portion integrally connected with the main body portion of said structure by a thin section of metal which substantially thermally isolates said auxiliary portion from said main body portion, positioning said structure in a mold and pouring molten metal around said auxiliary portion to thereby melt said auxiliary portion and a portion of said main body portion.

Description

Patented Oct. 19, 1943 METHOD FOR JOINING ALUMINUM STRUCTURES Kenton D.
New York McMahan, Scotia, N. Y., assignor to General Electric Comp any, a corporation ol' Application December 15,1941, Serial No. 422,99'i
Claims.
The present invention relates to a method for joining metals having substantially the same aluminum is cast around a solid aluminum structure an oxide film on the solid aluminum prevents fusion of the cast and solid metal. If a flux is employed in such a process, for example in joining an aluminum fan blade to a supporting aluminum structure by casting the supporting structure about the fan blade, there is a tendency to form a bond at the extreme end of the blade but the flux is merely added to the oxide layer on the blade and prevents fusion between the molten and the solid metal,
, and furthermore causes corrosion between the parts which eventually results in failure of the joint.
One of the objects of the present invention is to provide an eicient and reliable method for obtaining strong. sound junctions between metal structures having substantially equal melting points and particularly between aluminum or aluminum alloy structures. appear hereinafter.
The novel features which are characteristic of my invention are set forth with particularity in the appended claims. My invention, however, will best be understood from reference to the following specification when considered in connection with the accompanying drawing in which Fig. 1 is a cross sectional view of an aluminum fan blade positioned in a sand mold and embodying the features of my invention; Fig. 2 is a cross sectional view of the same blade after molten aluminum has been poured into the mold; Fig. 3 is a cross sectional View of a modified form of my invention; Fig. 4 is a view partly in elevation and partly in cross section of the fan blade and mold shown in Fig. 3; While Fig. 5 is a fan constructed in accordance with my invention.
In carrying out my invention, a structure which may be an aluminum fan blade I is positioned in a sand mold 2. In operation the blade I may be supported at opposite ends thereof Further objects will` as indicated in Fig. 5 of the drawing. The extreme outer end of the blade II is provided with a somewhat bulbous portion 3 which is shown as triangular in shape in Fig. 1 but may be any desired form. The part 3 is joined to the blade proper by means of a reduced, very thin section or junction 4. If desired. a small amount of flux 5 may be applied to the lower surface of the part 3, as indicated in Fig. 1, to facilitate transfer of heat from the molten metal into that part.
The problem of making the blade I fuse into a molten mass of aluminum is primarily one of heat transfer across an oxide layer and of heat conduction away from the junction 4 and through the blade I. Where a blade is employed which has a bulbous or dovetailed outer end portion 3 connected to the main body of the blade by a very narrow or thin section of metal asindicated in Fig. 1, the greatly reduced volume of metal in the narrow section substantially isolates the enlarged portion 3 from the main body of blade I with respect to thermal conductivity. This effect in combination with the ilux coated portion of the part 3 results in complete melting of that part when molten aluminum 6 is poured into the sand mold 2 and around the portion 3 of the blade. The oxide coating on the blade proper is thereby broken and the line of contact between the blade and molten metal widens tothe full thickness of the blade, as indicated by the shaded portion of Fig. 2 with the result that the end portion of the blade fuses into the molten metal and sets with it thereby forming a strong, durable bond.
During fusion, the oxide layer on the aluminum is pushed to the outer surface of the cast aluminum as indicated at 1 in Fig. 2 of the drawing. At this point the oxide layer is without harmful effect. When the enlarged or dovetailed portion 3 is completely melted any ilux 8 which has been applied to the outer surfaces will float to the outer surface of the cast aluminum as indicated in Fig. 2 and may be removed by a cleaning or machining operation.. In Figs. 1 and 2 the fan blade I is shown as having a somewhat enlarged portion 9 adjacent its outer end provided with opposite parallel grooves I0 and II. It is unnecessary, however, to employ either grooves or an enlarged section.
In Figs. 3 and 4 there is disclosed a substantially flat blade I2. The outer or lower end of this blade is provided with a yseries of closely adjacent punched-out portions I3 which give the eiect of a thin necked down or dovetailed section. When molten aluminum is poured around the outer end of the table I2 the thin sections Il act in substantially the same manner as the reduced section 4 shown in Fig. 1.
The word "aluminum as employed in the present specification and claims is intended to include aluminum base alloys as well as aluminum. Furthermore, while the present method is illustrated in connection with aluminum or aluminum alloys it may be employed in joining other metals. The metals to be joined, however, should have substantially the same melting point.
What I claim as new and desire to secure by Letters Patent of the United states, is:
1. The method of joining two aluminum struc- 'A tures which comprises providing a bulbous portion connected to the main body portion through a reduced section of metal to thereby substantially thermally isolate said bulbous portion from the main body portion of said structure. positioning said aluminum structure in a mold and pouring molten aluminum around said reduced section and bulbous portion.
2. The method of joining two aluminum structures which comprises materially reducing the volume of metal in one of said structures adjacent one end thereof to thereby provide a greatly restricted passage for heat transfer between the end body portion and main body portion of said structure, positioning said structure in a mold and pouring molten aluminum into said mold to thereby surround and melt said end portion.
3. 'I'he method of joining two aluminum structures which comprises materially reducing the volume of metal in one of said structures adjacent one end thereof to thereby substantially thermally isolate said end portion of said structure from the main body portion thereof, positioning said structure in a mold and pouring molten aluminum therein to thereby melt said end portion and reduced portion of said structure.
4. The method of joining two aluminum structures which comprises materially reducing the volume of metal in one of said structures adjacent one end thereof to thereby substantially thermally isolate said end portion of said structure from the main body portion thereof, positioning said structure in a mold and pouring molten aluminum around said reduced portion and the portions of said structure adjacent thereto whereby said molten metal when cooled forms an integral structure with said first-mentioned structure.
5. The method of joining two metal structures having substantially equal melting points which comprises providing one of said structures with an auxiliary portion integrally connected with the main body portion of said structure by a thin section of metal which substantially thermally isolates said auxiliary portion from said main body portion, positioning said structure in a mold and pouring molten metal around said auxiliary portion to thereby melt said auxiliary portion and a portion of said main body portion.
KENTON D. MCMAHAN.
US422997A 1941-12-15 1941-12-15 Method for joining aluminum structures Expired - Lifetime US2332330A (en)

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Cited By (19)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2653547A (en) * 1947-03-01 1953-09-29 Borg Warner Hydrodynamic coupling
US2702613A (en) * 1950-08-07 1955-02-22 Dayton Steel Foundry Co Brake drum construction
US2858262A (en) * 1943-11-16 1958-10-28 Robert F Plott Protectively covered article and method of manufacture
US2908223A (en) * 1954-06-03 1959-10-13 Buchi Alfred Impeller for centrifugal blowers or pumps
US2980562A (en) * 1957-08-12 1961-04-18 Gen Motors Corp Method of soldering and flux therefor
US3008200A (en) * 1959-06-11 1961-11-14 Horace W Olsen Method of and apparatus for casting cored castings
US3088192A (en) * 1957-04-26 1963-05-07 Int Nickel Co Method of joining turbine blade parts
US3207207A (en) * 1962-05-14 1965-09-21 Congdon R J Max Die-cast casement window construction
US3246699A (en) * 1964-06-10 1966-04-19 Outboard Marine Corp Propeller
US4664609A (en) * 1983-12-14 1987-05-12 Honda Giken Kogyo Kabushiki Kaisha Vane holder for vane pump and method of making same
US4971536A (en) * 1987-03-30 1990-11-20 Aisin Seiki Kabushiki Kaisha Rotor for fluidic apparatus
US5069265A (en) * 1989-01-25 1991-12-03 Pcc Airfoils, Inc. Method of making a turbine engine component
US6085830A (en) * 1997-03-24 2000-07-11 Fujikura Ltd. Heat sink, and process and apparatus for manufacturing the same
ITBO20090069A1 (en) * 2009-02-11 2010-08-12 Elenos S R L HEAT SINK FOR ELECTRONIC POWER COMPONENTS AND METHOD FOR THE PRODUCTION OF THE SAME
US20110206518A1 (en) * 2008-09-05 2011-08-25 Alstom Hydro France Francis-type runner for a hydraulic machine, hydraulic machine including such a runner, and method for assembling such a runner
US20140345136A1 (en) * 2011-12-18 2014-11-27 Cooler Master Development Corporation Heat dissipating fin, heat dissipating device and method of manufacturing the same
US9611748B2 (en) 2013-12-06 2017-04-04 Honeywell International Inc. Stationary airfoils configured to form improved slip joints in bi-cast turbine engine components and the turbine engine components including the same
US10294807B2 (en) 2016-05-19 2019-05-21 Honeywell International Inc. Inter-turbine ducts
US20210215054A1 (en) * 2020-01-15 2021-07-15 Honeywell International Inc. Turbine nozzle compliant joints and additive methods of manufacturing the same

Cited By (22)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2858262A (en) * 1943-11-16 1958-10-28 Robert F Plott Protectively covered article and method of manufacture
US2653547A (en) * 1947-03-01 1953-09-29 Borg Warner Hydrodynamic coupling
US2702613A (en) * 1950-08-07 1955-02-22 Dayton Steel Foundry Co Brake drum construction
US2908223A (en) * 1954-06-03 1959-10-13 Buchi Alfred Impeller for centrifugal blowers or pumps
US3088192A (en) * 1957-04-26 1963-05-07 Int Nickel Co Method of joining turbine blade parts
US2980562A (en) * 1957-08-12 1961-04-18 Gen Motors Corp Method of soldering and flux therefor
US3008200A (en) * 1959-06-11 1961-11-14 Horace W Olsen Method of and apparatus for casting cored castings
US3207207A (en) * 1962-05-14 1965-09-21 Congdon R J Max Die-cast casement window construction
US3246699A (en) * 1964-06-10 1966-04-19 Outboard Marine Corp Propeller
US4664609A (en) * 1983-12-14 1987-05-12 Honda Giken Kogyo Kabushiki Kaisha Vane holder for vane pump and method of making same
US4971536A (en) * 1987-03-30 1990-11-20 Aisin Seiki Kabushiki Kaisha Rotor for fluidic apparatus
US5069265A (en) * 1989-01-25 1991-12-03 Pcc Airfoils, Inc. Method of making a turbine engine component
US6085830A (en) * 1997-03-24 2000-07-11 Fujikura Ltd. Heat sink, and process and apparatus for manufacturing the same
US6253829B1 (en) * 1997-03-24 2001-07-03 Fujikura Ltd. Heat sink, and process and apparatus for manufacturing the same
US20110206518A1 (en) * 2008-09-05 2011-08-25 Alstom Hydro France Francis-type runner for a hydraulic machine, hydraulic machine including such a runner, and method for assembling such a runner
US9175662B2 (en) * 2008-09-05 2015-11-03 Alstom Renewable Technologies Francis-type runner for a hydraulic machine, hydraulic machine including such a runner, and method for assembling such a runner
ITBO20090069A1 (en) * 2009-02-11 2010-08-12 Elenos S R L HEAT SINK FOR ELECTRONIC POWER COMPONENTS AND METHOD FOR THE PRODUCTION OF THE SAME
US20140345136A1 (en) * 2011-12-18 2014-11-27 Cooler Master Development Corporation Heat dissipating fin, heat dissipating device and method of manufacturing the same
US9611748B2 (en) 2013-12-06 2017-04-04 Honeywell International Inc. Stationary airfoils configured to form improved slip joints in bi-cast turbine engine components and the turbine engine components including the same
US10294807B2 (en) 2016-05-19 2019-05-21 Honeywell International Inc. Inter-turbine ducts
US20210215054A1 (en) * 2020-01-15 2021-07-15 Honeywell International Inc. Turbine nozzle compliant joints and additive methods of manufacturing the same
US11156113B2 (en) * 2020-01-15 2021-10-26 Honeywell International Inc. Turbine nozzle compliant joints and additive methods of manufacturing the same

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