Flux cored preforms for brazing

Abstract

A wire preform suitable for use in brazing components to one another. The preform is made from a length of wire having a core of flux material, and a longitudinal seam or gap that extends over the length of the wire. The seam is formed so that when heated, the flux material flows from the core and out of the seam. The length of wire is in the form of a loop having a certain circumference so that when the preform is heated, the flux material disperses uniformly from the circumference of the preform for evenly treating the surface of a component on which the preform is placed. The length of wire may include a silver alloy.

1. A wire preform  suitable for use in brazing  joining components to one another, comprising:
 a length of wire having a core of a flux material, and a longitudinal seam or gap  extending over the length of the wire wherein the seam is formed so that when heated, the flux material flows from the core and out of the seam of the wire; and  
 the length of wire is in the  a form of a loop having a certain circumference  so that when the preform is  heated, flux material is dispersed uniformly from the circumference of the preform  therefrom for evenly treating a component surface on which the preform is disposed .  
 
     
     
       2. A wire preform  according to  claim 1 , wherein the length of wire is formed from an elongate metal sheet, and the seam of the wire is defined by an inner edge portion of the sheet and a confronting outer edge portion of the sheet. 
     
     
       3. A wire preform  according to  claim 2 , wherein the inner edge portion of the metal sheet is angled to be embedded in the flux material. 
     
     
       4. A wire preform  according to  claim 1 , wherein the seam on the length of wire is on the  an inner circumference of the  a ring preform. 
     
     
       5. A wire preform  according to  claim 1 , wherein the length of wire is preformed in a helical in form  shape. 
     
     
       6. A wire preform  according to  claim 5 , wherein the seam is on the  a circumference of the preform. 
     
     
       7. A wire preform  according to  claim 1 , wherein the wire has a diameter of between about 0.031 inch and about 0.125 inch. 
     
     
       8. A wire preform  according to  claim 1 , wherein the length of wire comprises a silver alloy. 
     
     
       9. The wire of  claim 1 , wherein the wire includes:
   a rolled metal alloy sheet that defines an encasing perimeter that extends around the flux material of the core;        an inner angled edge portion of the sheet is embedded in the flux material and emerges from the core and the sheet to extend around the flux material; and        an outer edge portion of the sheet confronts the sheet proximate a location where the inner angled edge portion of the sheet emerges from the core, thereby forming a seam.     
     
     
       10. A wire according to  claim 1 , wherein the length of wire is in the form of a loop having a certain circumference to aid in dispersion of flux material from an inner circumference of the loop during brazing. 
     
     
       11. The wire of  claim 10 , wherein a laser aids with wire and flux formation. 
     
     
       12. The wire of  claim 1 , wherein the wire may be at least one of: an oval, a square, a multi- form helical loop; a braze ring; a helical shape having a circular cross - section; and a wire having a diameter between about  0 . 031  and about  0 . 125  inches.   
     
     
       13. The wire of  claim 1 , wherein when the wire reaches a brazing temperature between approximately  500  and approximately  1100  degrees F., flux is dispersed from the seam uniformly along a circumference of the wire. 
     
     
       14. The wire of  claim 1 , wherein
   the length of wire is formed from a metal alloy sheet is formed into a U - shaped channel by a die;        the U - shaped channel is then passed through a trough by pulling the metal alloy sheet in a direction away from a dispensing apparatus;        wherein the flux material is a powdered flux material conveyed from a dispenser to fill the U - shaped channel;        the filled channel is passed out of the trough and through a die where the filled channel begins to close;        the metal alloy then passes through a die where the channel is closed and a butt seam is formed with opposing side edge portions of the channel;        a path for the flux material is created in a center of the core to aid in release of the flux material from the core;        the metal alloy then passes through another die where the metal alloy is formed to its final size diameter, while maintaining the path.     
     
     
       15. The wire of  claim 14 , wherein the wire is then packaged in spools. 
     
     
       16. The wire of  claim 1 , wherein the metal alloy sheet is an alloy of at least one of the following: aluminum- silicone; zinc - aluminum; copper zinc; silver - copper - zinc; silver - copper - zinc - tin; silver - copper - zinc - tin - nickel; silver - copper - zinc - nickel; silver - copper - tin; silver - copper - zinc - manganese - nickel; silver - copper - zinc - cadmium; and silver - copper - zinc - cadmium.   
     
     
       17. The wire of  claim 14 , wherein the metal alloy sheet is a narrow elongate strip coiled onto a spool to facilitate feeding of the metal alloy during a manufacturing process. 
     
     
       18. The wire of  claim 1 , wherein the wire is formed into a brazing wire having a size and a cross section of a desired shape and adopting a configuration that is complementary to various angles and sizes of surfaces to be brazed. 
     
     
       19. A brazing wire suitable for use in joining components to one another by brazing, comprising: a length of wire having a core of a flux material, and a longitudinal seam extending over the length of the wire wherein the seam is formed so that when the wire is heated, the flux material flows from the core and out of the seam of the wire and is dispersed uniformly therefrom for evenly treating components to be joined. 
     
     
       20. A wire suitable for use in joining components to one another by brazing, comprising:
   a length of wire having a core of a flux material surrounded by a metal sheet, and a longitudinal seam extending along the length of the wire;        an inner angled edge portion of the sheet embedded in the flux material; and        an outer edge portion of the sheet confronting the inner angled portion of the sheet proximate a location where the inner angled edge portion of the sheet emerges from the core;        wherein the length of wire is in a form so that the seam is at an inner surface to aid in dispersion of flux material from the inner surface during heating;        wherein when the wire is heated, the flux material becomes molten and flows from the core and out of the seam of the wire;        wherein the molten flux material treats components in preparation for brazing.