Vacuum braze cycle for clad aluminum sheet

Claim 1

A method for manufacturing a braze bonded aluminum sheet structure comprising arranging clad aluminum sheet components in an assembly having a seam between the components, said aluminum sheet components including a braze cladding composed of hypoeutectic aluminum-silicon alloy containing magnesium, and carrying an oxide film on the surface thereof, and brazing the assembly by heating the cladding to melt the braze alloy and to cause the molten braze alloy to flow into the seam, said brazing further comprising initially heating the cladding to a first temperature to vaporize magnesium from the braze alloy, heating to a second, relatively higher temperature to melt a portion of the braze alloy without initiating significant alloy flow into the seam, maintaining the cladding at said second temperature for a time effective to vaporize residual magnesium from the braze alloy and to disrupt the surface oxide film by exudation, and thereafter heating the assembly to a third temperature sufficient to complete melting of the cladding and to effectuate flow of the molten alloy into the seam, whereafter the braze alloy cools and solidifies to form a braze bond between the components.

Claim 2

A method for manufacturing a braze bonded aluminum sheet structure comprising arranging clad aluminum sheet components in an assembly having a seam between the components, said aluminum sheet components including a braze cladding composed of hypoeutectic aluminum-silicon alloy containing magnesium, and carrying an oxide film on the surface thereof, and brazing the assembly by heating the cladding to melt the braze alloy and to cause the molten braze alloy to flow into the seam, said brazing further comprising initially heating the cladding to a first temperature to vaporize magnesium from the braze alloy, heating to a second, relatively higher temperature to melt a portion of the braze alloy without initiating significant alloy flow into the seam, maintaining the cladding at said second temperature for a time effective to vaporize residual magnesium from the braze alloy and to disrupt the surface oxide film by exudation, and thereafter heating the assembly to a third temperature sufficient to complete melting of the cladding and to effectuate flow of the molten alloy into the seam, whereafter the braze alloy cools and solidifies to form a braze bond between the components.

Claim 3

A method for manufacturing a braze bonded aluminum sheet structure comprising arranging clad aluminum sheet components in an assembly having a seam between the components, said aluminum sheet components including a braze alloy cladding composed of between about 9 and 11 weight percent silicon and between about 0.07 and 0.25 weight percent magnesium, brazing the assembly by heating the cladding to melt the braze alloy and flowing the molten braze alloy into the seam, said brazing comprising the step of initially heating the assembly at a temperature between about 1071° F. and 1073° F. for between 7 and 10 minutes to partially melt the braze alloy prior to flow of the braze alloy, and thereafter heating to a relatively high temperature to complete melting of the cladding and to cause the molten alloy to flow into the seam, whereafter the braze alloy cools and solidifies to form a braze bond between the components.

Claim 4

A method for manufacturing a braze bonded aluminum sheet structure comprising arranging clad aluminum sheet components in an assembly having a seam between the components, said aluminum sheet components including a braze alloy cladding composed of between about 9 and 11 weight percent silicon and between about 0.07 and 0.25 weight percent magnesium, brazing the assembly by heating the cladding to melt the braze alloy and flowing the molten braze alloy into the seam, said brazing comprising the step of initially heating the assembly at a temperature between about 1071° F. and 1073° F. for between 7 and 10 minutes to partially melt the braze alloy prior to flow of the braze alloy, and thereafter heating to a relatively high temperature to complete melting of the cladding and to cause the molten alloy to flow into the seam, whereafter the braze alloy cools and solidifies to form a braze bond between the components.