Layered products for fluxless brazing of substrates

Abstract

A brazing product for fluxless brazing comprises a substrate and a filler metal-forming composition applied to the substrate. The substrate preferably comprises aluminum, an aluminum alloy or another metal and may include at least one layer of a ceramic, carbide or nitride. The filler metal-forming composition comprises a liquid-forming layer comprising silicon and a braze-promoting layer comprising one or more metals selected from the group comprising nickel, cobalt, palladium and iron. The liquid-forming layer comprises one or more material layers. Where the liquid-forming layer comprises a plurality of layers, it may include at least one layer consisting essentially of silicon.

1 . A brazing product for fluxless brazing, comprising: 
 (a) a substrate; and    (b) a filler metal-forming composition applied to the substrate, wherein the filler metal-forming composition forms a liquid filler metal when the brazing product is heated to a brazing temperature, and wherein the filler metal-forming composition comprises: 
 (i) a liquid-forming layer comprising silicon, wherein the silicon content of the liquid-forming layer is from about 20 to 100 percent by weight; and  
 (ii) a braze-promoting layer comprising one or more metals selected from the group comprising nickel, cobalt, palladium and iron.  
   
   
   
       2 . The brazing product according to  claim 1 , wherein the liquid-forming layer is applied on top of the substrate and the braze-promoting layer is applied on top of the liquid-forming layer.  
   
   
       3 . The brazing product according to  claim 2 , wherein the substrate has an outermost metal layer on top of which the braze-promoting layer is applied.  
   
   
       4 . The brazing product according to  claim 1 , wherein the substrate comprises at least one layer of aluminum or an aluminum alloy.  
   
   
       5 . The brazing product according to  claim 4 , wherein the substrate comprises at least one layer of an aluminum alloy selected from the group consisting of AA1xxx, AA2xxx, AA3xxx, AA4xxx, AA5xxx, AA6xxx, AA7xxx and M8xxx-series alloys, and aluminum casting alloys.  
   
   
       6 . The brazing product of  claim 5 , comprising an aluminum brazing sheet or an aluminum casting clad with said filler metal-forming composition.  
   
   
       7 . The brazing product of  claim 1 , wherein the substrate comprises at least one layer of a dissimilar metal selected from the group consisting of copper, copper alloys such as bronze and brass, high strength steel, low carbon steel, stainless steel, nickel alloy steel, titanium and titanium alloys.  
   
   
       8 . The brazing product of  claim 7 , wherein said dissimilar metal layer is selected from the group consisting of copper, copper alloys, high strength steel, low carbon steel, stainless steel, nickel alloy steel, and wherein the dissimilar metal layer is coated or plated with a metal selected from the group consisting of aluminum, titanium and nickel.  
   
   
       9 . The brazing product of  claim 1 , wherein the substrate includes at least one layer comprising a ceramic, a carbide or a nitride.  
   
   
       10 . The brazing product of  claim 1 , wherein the liquid-forming layer is comprised of a single material layer.  
   
   
       11 . The brazing product of  claim 1 , wherein the liquid-forming layer is comprised of a plurality of material layers having the same or different composition.  
   
   
       12 . The brazing product of  claim 1 , wherein the liquid-forming layer has a thickness of from about 1-50 μm.  
   
   
       13 . The brazing product of  claim 1 , wherein the liquid-forming layer has a thickness of from about 1-30 μm.  
   
   
       14 . The brazing product of  claim 1 , wherein the liquid-forming layer has a thickness of from about 10-20 μm.  
   
   
       15 . The brazing product of  claim 1 , wherein the liquid-forming layer has a thickness of from about 5-10 μm.  
   
   
       16 . The brazing product of  claim 1 , wherein the liquid-forming layer comprises at least 30 percent by weight silicon.  
   
   
       17 . The brazing product of  claim 1 , wherein the liquid-forming layer comprises at least 50 percent by weight silicon.  
   
   
       18 . The brazing product of  claim 1 , wherein the liquid-forming layer comprises from about 90-100 percent by weight silicon.  
   
   
       19 . The brazing product of  claim 1 , wherein the liquid-forming layer further comprises aluminum.  
   
   
       20 . The brazing product of  claim 19 , wherein the liquid-forming layer comprises a plurality of material layers comprising aluminum and a plurality of material layers comprising silicon, wherein the aluminum and silicon layers are arranged in alternating orders within the liquid-forming layer.  
   
   
       21 . The brazing product of  claim 20 , wherein an outermost one of said alternating layers, which is applied directly under the braze-promoting layer, comprises silicon.  
   
   
       22 . The brazing product of  claim 21 , wherein said outermost silicon layer has a thickness of about 1 μm.  
   
   
       23 . The brazing product of  claim 19 , wherein the liquid-forming layer includes at least one layer which comprises an alloy of silicon and aluminum.  
   
   
       24 . The brazing product of  claim 23 , wherein the alloy of silicon and aluminum further comprises one or more metals selected from the group consisting of magnesium, zinc and copper.  
   
   
       25 . The brazing product of  claim 1 , wherein the braze-promoting layer comprises nickel.  
   
   
       26 . The brazing product of  claim 25 , wherein the braze-promoting layer further comprises one or more alloying elements selected from the group comprising cobalt, iron, lead, bismuth, magnesium, lithium, antimony and thallium.  
   
   
       27 . The brazing product of  claim 25 , wherein the braze-promoting layer comprises a nickel-based alloy selected from the group consisting of nickel-bismuth, nickel-lead, nickel-cobalt, nickel-bismuth-cobalt, nickel-lead-cobalt, nickel-lead-bismuth and nickel-bismuth-antimony.  
   
   
       28 . The brazing product of  claim 1 , wherein the braze-promoting layer has a thickness of 0.05 to about 1.0 microns.  
   
   
       29 . The brazing product of  claim 1 , wherein the filler metal-forming composition further comprises a braze modifier layer located at an interface between the liquid-forming layer and the braze-promoting layer or at an interface between the substrate and the liquid-forming layer, wherein the braze modifier layer comprises one or more metals selected from the group consisting of bismuth, lead, lithium, antimony, magnesium, strontium and copper.  
   
   
       30 . The brazing product of  claim 29 , wherein the braze modifier layer has a thickness of from about 5 to 50 nanometers.  
   
   
       31 . The brazing product of  claim 29 , wherein the braze-promoting layer comprises nickel and wherein the braze modifier layer comprises bismuth or lead.  
   
   
       32 . The brazing product of  claim 29 , wherein the braze modifier layer comprises lithium which is deposited in the form of an aluminum-lithium alloy.  
   
   
       33 . The brazing product of  claim 29 , wherein the braze modifier layer comprises antimony which is deposited in the form of an alloy with aluminum or zinc.  
   
   
       34 . The brazing product of  claim 1 , wherein the filler metal-forming composition further comprises a bonding layer which is located at an interface between the substrate and the liquid-forming layer, and wherein the bonding layer comprises one or more elements selected from the group consisting of aluminum, zinc and silicon.  
   
   
       35 . The brazing product of  claim 34 , wherein the bonding layer has a thickness of about 1 micron.  
   
   
       36 . The brazing product of  claim 1 , further comprising a barrier coating to temporarily restrict diffusion of silicon from the liquid-forming layer into the substrate, wherein the barrier coating comprises one or more elements selected from the group consisting of nickel, titanium, tantalum, copper, niobium, tin, lead, bismuth and aluminum, and wherein the barrier coating is located between the substrate and the liquid-forming layer.  
   
   
       37 . The brazing product of  claim 1 , wherein the braze-promoting layer has a thickness of no more than 25 percent of a thickness of the liquid-forming layer.  
   
   
       38 . The brazing product of  claim 1 , wherein the braze-promoting layer comprises no more than 25 percent by weight of the filler metal-forming composition.  
   
   
       39 . The brazing product of  claim 1 , wherein the silicon content of the filler metal-forming composition as a whole is not less than about 20 percent by weight.  
   
   
       40 . A brazing product for fluxless brazing, comprising: 
 (a) a substrate; and    (b) a filler metal-forming composition applied to the substrate, wherein the filler metal-forming composition forms a liquid filler metal when the brazing product is heated to a brazing temperature, and wherein the filler metal-forming composition comprises: 
 (i) a liquid-forming layer comprising silicon, wherein the liquid-forming layer comprises one or more material layers, and wherein at least one of said material layers consists essentially of silicon; and  
 (ii) a braze-promoting layer comprising one or more metals selected from the group comprising nickel, cobalt, palladium and iron.  
   
   
   
       41 . The brazing product of  claim 40 , wherein the liquid-forming layer comprises a plurality said layers consisting essentially of silicon.  
   
   
       42 . The brazing product of  claim 40 , wherein said at least one layer consisting essentially of silicon has a silicon content of from about 90-100 percent by weight.  
   
   
       43 . The brazing product of  claim 40 , wherein said at least one layer consisting essentially of silicon has a silicon content of from about 95-100 percent by weight.