Method for depositing braze alloy

Abstract

The present invention relates to a method for depositing braze alloy on a surface of a component that will be subsequently joined to a second component. In one form a braze alloy is sprayed by a thermal process. The braze alloy is sprayed in such a fashion that substantially all of the powder braze alloy is unmolten, but is heated to a state deformable enough to bond to the surface. One form of the spraying operation utilizes a High Velocity Oxygen Fuel spray gun.

What is claimed is:  
     
         1 . A method comprising: 
 providing a powder braze alloy; and    thermally spraying the powder braze alloy and onto a surface in such a state that substantially all the powder braze alloy is unmolten but is heated to a state deformable enough to bond to the surface.    
     
     
         2 . The method of    claim 1   , wherein said spraying is a High Velocity Oxygen Fuel process, and wherein said spraying preplaces the braze alloy on the surface.  
     
     
         3 . The method of    claim 2   , wherein the High Velocity Oxygen Fuel process utilizes H 2  as its fuel.  
     
     
         4 . The method of    claim 3   , wherein the spray distance is about 9 inches.  
     
     
         5 . The method of    claim 4   , which further includes roughening and degreasing the surface.  
     
     
         6 . The method of    claim 4   , wherein the braze alloy is a nickel super alloy.  
     
     
         7 . The method of    claim 4   , wherein the melting point suppressant is boron.  
     
     
         8 . The method of    claim 6   , wherein the melting point suppressant is boron.  
     
     
         9 . The method of    claim 8   , which further comprises preheating the surface to a temperature of at least 150 degrees Fahrenheit.  
     
     
         10 . The method of    claim 9   , wherein the High Velocity Oxygen Fuel process utilizes a Diamond Jet 2600 spray gun.  
     
     
         11 . The method of    claim 10   , wherein the spray gun utilizes a powder feed rate of about 5 pounds per hour.  
     
     
         12 . The method of    claim 11   , wherein the flame velocity is about 4,000 ft./sec.  
     
     
         13 . The method of    claim 1   , wherein: 
 said spraying is a High Velocity Oxygen Fuel process utilizing H 2  as a fuel;    said spraying preplaces the braze alloy on the surface;    said providing includes a nickel super alloy as the braze alloy and boron as the melting point suppressant; and    which further comprises preheating the surface to a temperature of at least 150 degrees Fahrenheit.    
     
     
         14 . The method of    claim 2   , wherein the High Velocity Oxygen Fuel process utilizes a neutral flame.  
     
     
         15 . The method of    claim 2   , wherein the High Velocity Oxygen Fuel process utilizes a fuel rich flame.  
     
     
         16 . The method of    claim 13   , wherein the High Velocity Oxygen Fuel process utilizes a neutral flame.  
     
     
         17 . The method of    claim 13   , wherein the High Velocity Oxygen Fuel process utilizes a fuel rich flame.  
     
     
         18 . A method comprising: 
 providing a powder braze alloy; and    thermally spraying the powder braze alloy at a high velocity onto a surface in such a state that substantially all the powder braze alloy is unmolten but is heated to a state malleable enough to bond to the surface.    
     
     
         19 . The method of    claim 18   , wherein said spraying is a High Velocity Oxygen Fuel process, and wherein said spraying preplaces the braze alloy on the surface.  
     
     
         20 . The method of    claim 19   , wherein the High Velocity Oxygen Fuel process has H 2  as its fuel.  
     
     
         21 . The method of    claim 20   , wherein the velocity of the powder is about 1,200 ft./sec. to 1600 ft/sec.  
     
     
         22 . The method of    claim 21   , wherein the carrier gas is N 2 .  
     
     
         23 . The method of    claim 21   , wherein the spray distance is about 9 inches.  
     
     
         24 . The method of    claim 23   , which further includes roughening and degreasing the surface.  
     
     
         25 . The method of    claim 23   , wherein the braze alloy is a nickel super alloy.  
     
     
         26 . The method of    claim 23   , wherein the melting point suppressant is boron.  
     
     
         27 . The method of    claim 25   , wherein the melting point suppressant is boron.  
     
     
         28 . The method of    claim 26   , which further comprises preheating the surface to a temperature of at least 150 degrees Fahrenheit.  
     
     
         29 . The method of    claim 27   , wherein the High Velocity Oxygen Fuel process utilizes a Diamond Jet 2600 spray gun.  
     
     
         30 . The method of    claim 28   , wherein the spray gun utilizes a powder feed rate of about 5 pounds per hour.  
     
     
         31 . The method of    claim 18   , wherein: 
 said spraying is a High Velocity Oxygen Fuel process utilizing H 2  as a fuel;    said spraying preplaces the braze alloy on the surface;    said providing includes a nickel super alloy as the braze alloy; and    which further comprises preheating the surface to a temperature of at least 150 degrees Fahrenheit.    
     
     
         32 . A method comprising: 
 providing a powder braze alloy; and    flame spraying the powder braze alloy at a high velocity onto a surface in such a state that substantially all the powder braze alloy is unmolten but is heated to a state malleable enough to bond to the surface.    
     
     
         33 . The method of    claim 32   , wherein said flame spraying utilizes a neutral flame.  
     
     
         34 . The method of    claim 33   , wherein said flame spraying is a High Velocity Oxygen Fuel process, and wherein said spraying preplaces the powder braze alloy on the surface.  
     
     
         35 . The method of    claim 34   , wherein the High Velocity Oxygen Fuel process utilizes H 2  as its fuel.  
     
     
         36 . The method of    claim 35   , wherein the flame velocity is about 4,000 ft./sec.  
     
     
         37 . The method of    claim 36   , wherein the carrier gas is N 2 .  
     
     
         38 . The method of    claim 36   , wherein the spray distance is about 9 inches.  
     
     
         39 . The method of    claim 38   , which further includes the steps of roughening and degreasing the surface.  
     
     
         40 . The method of    claim 38   , wherein the braze alloy is a nickel super alloy.  
     
     
         41 . The method of    claim 38   , wherein the melting point suppressant is boron.  
     
     
         42 . The method of    claim 40   , wherein the melting point suppressant is boron.  
     
     
         43 . The method of    claim 42   , which further comprises preheating the surface to a temperature of at least 150 degrees Fahrenheit.  
     
     
         44 . The method of    claim 43   , wherein the High Velocity Oxygen Fuel process utilizes a Diamond Jet 2600 spray gun.  
     
     
         45 . The method of    claim 44   , wherein the spray gun utilizes a powder feed rate of about 5 pounds per hour.  
     
     
         46 . The method of    claim 32   , wherein said flame spraying utilizes a fuel rich flame.  
     
     
         47 . The method of    claim 46   , wherein said flame spraying is a High Velocity Oxygen Fuel process, and wherein said spraying preplaces the powder braze alloy on the surface.  
     
     
         48 . The method of    claim 47   , wherein the High Velocity Oxygen Fuel process utilizes H 2  as its fuel.  
     
     
         49 . The method of    claim 48   , wherein the velocity of the powder is about 1,200 ft./sec. to 1,600 ft./sec.  
     
     
         50 . The method of    claim 49   , wherein the carrier gas is N 2 .  
     
     
         51 . The method of    claim 49   , wherein the spray distance is about 9 inches.  
     
     
         52 . The method of    claim 51   , which further includes the steps of roughening and degreasing the surface.  
     
     
         53 . The method of    claim 51   , wherein the braze alloy is a nickel super alloy.  
     
     
         54 . The method of    claim 51   , wherein the melting point suppressant is boron.  
     
     
         55 . The method of    claim 53   , wherein the melting point suppressant is boron.  
     
     
         56 . The method of    claim 55   , which further comprises preheating the surface to a temperature of at least 150 degrees Fahrenheit.  
     
     
         57 . The method of    claim 56   , wherein the High Velocity Oxygen Fuel process utilizes a Diamond Jet 2600 spray gun.  
     
     
         58 . The method of    claim 57   , wherein the spray gun utilizes a powder feed rate of about 5 pounds per hour.  
     
     
         59 . The method of    claim 32   , wherein: 
 said flame spraying is a High Velocity Oxygen Fuel process utilizing H 2  as a fuel;    said flame spraying utilizes a neutral flame;    said flame spraying preplaces the braze alloy on the surface;    said providing includes a nickel super alloy as the braze alloy; and    which further comprises preheating the surface to a temperature of at least 150 degrees Fahrenheit.    
     
     
         60 . The method of    claim 32   , wherein: 
 said flame spraying is a High Velocity Oxygen Fuel process utilizing H 2  as a fuel;    said flame spraying utilizes a fuel rich flame;    said flame spraying preplaces the braze alloy on the surface;    said providing includes a nickel super alloy as the braze alloy; and    which further comprises preheating the surface to a temperature of at least 150 degrees Fahrenheit.