Weld metal material apparatus and method

Abstract

A solid weld-metal-producing material is formed by agglomerating weld metal material powder. An igniter may be integrally formed in or on the agglomerated weld metal material. In addition to typical components of a weld metal material mixture, such as a reductant metal and a transition metal oxide, the agglomerated weld metal mixture may include a binder material, such as sodium silicate. In addition to functioning as a binder to help hold the agglomerated weld metal material together, the binder material may aid in the exothermic reaction that occurs when the weld metal material is ignited. The agglomerated weld metal material may be made by mixing together a reductant metal powder, a transition metal oxide powder, and possibly a binder solution. A slurry of the components may be pressed together, for example, using a die and a ram, and then may be dried.

1 . A device for producing molten weld metal material, the device comprising: 
 a solid agglomeration capable of producing flowable weld metal material, including: 
 a metallic compound; and  
 a reducing agent.  
   
     
     
         2 . The device of  claim 1 , further comprising an igniter operatively coupled to the agglomeration.  
     
     
         3 . The device of  claim 2 , wherein the igniter is an electrical igniter.  
     
     
         4 . The device of  claim 3 , wherein the electrical igniter includes a pair of wires with a spark gap therebetween.  
     
     
         5 . The device of  claim 3 , wherein the electrical igniter includes: 
 a pair of metal strips; and    a insulator strip between the pair of metal strips;    wherein the strips have a conical hole therethrough.    
     
     
         6 . The device of  claim 3 , wherein the electrical igniter includes: 
 a resistor on or in the agglomeration; and    a pair of wires coupled to the resistor, for providing current through the resistor.    
     
     
         7 . The device of  claim 2 , wherein the igniter includes a chemically-reactive starting powder that may be ignited to initiate a chemical reaction in the agglomeration.  
     
     
         8 . The device of  claim 2 , wherein the igniter is integrally mechanically coupled to the agglomeration.  
     
     
         9 . The device of  claim 8 , wherein part of the igniter is embedded in the agglomeration.  
     
     
         10 . The device of  claim 1 , wherein the reducing agent includes a reductant metal powder.  
     
     
         11 . The device of  claim 10 , wherein the reductant metal powder includes one or more of aluminum powder and copper powder.  
     
     
         12 . The device of  claim 1 , wherein the metallic compound powder includes a metal oxide powder.  
     
     
         13 . The device of  claim 12 , wherein the metal oxide powder includes a transition metal oxide powder.  
     
     
         14 . The device of  claim 13 , wherein the transition metal oxide powder includes one or more of iron oxide, copper oxide, manganese dioxide, and titanium dioxide.  
     
     
         15 . The device of  claim 1 , wherein the solid agglomeration further includes a mechanical binder.  
     
     
         16 . The device of  claim 15 , wherein the binder includes sodium silicate.  
     
     
         17 . A method of coupling together two or more conductors, the method comprising: 
 placing respective parts of the conductors in a weld chamber of a mold;    placing an agglomeration of weld-metal-producing material in a crucible of the mold;    igniting the agglomeration to produce molten weld metal material in the crucible; and    flowing the molten weld metal material into the mold chamber to thereby couple together the conductors.    
     
     
         18 . The method of  claim 17 , wherein the placing the agglomeration includes placing an agglomeration that includes: 
 a metallic compound; and    a reducing agent.    
     
     
         19 . The method of  claim 18 , wherein the agglomeration further includes a mechanical binder.  
     
     
         20 . The method of  claim 17 , wherein the igniting includes electrically igniting the agglomeration using an electrical igniter that is mechanically coupled to the agglomeration.  
     
     
         21 . The method of  claim 17 , wherein the placing the agglomeration includes placing plural agglomerations of weld-metal-producing material in the crucible.  
     
     
         22 . A method of fabricating a device for producing molten weld metal material, the method comprising: 
 forming a slurry that includes a metallic compound powder, a reductant metal powder, a binder material, and a liquid;    pressing the slurry to remove some of the liquid from the slurry, and to reduce the volume of the slurry; and    drying the pressed slurry to produce an agglomeration of weld-metal-producing material.    
     
     
         23 . The method of  claim 22 , wherein the pressing includes: 
 placing the slurry in a die; and    pressing the slurry with a ram;    
     
     
         24 . The method of  claim 22 , further comprising mechanically coupling an electrical igniter to the agglomeration.  
     
     
         25 . The method of  claim 22 , wherein the pressing includes reducing the volume of the agglomeration at least about 20% below that of the powders that make up the slurry.