Filler metal with flux for brazing and soldering and method of making and using same
A wire ( 10 ) for use in a brazing or soldering operation has an elongated body ( 12 ) of a metallic material. The elongated body ( 12 ) has an outer surface ( 18 ). A channel ( 14 ) is formed along a length of the body. The channel ( 14 ) has an opening (A 1 ). A flux solution ( 22 ) is deposited within the channel ( 14 ) and along the length of the body. The flux solution ( 22 ) covers a portion of the outer surface ( 18 ). A portion of the flux solution ( 22 ) is exposed through the opening (A 1 ) in the channel ( 14 ).
1. A wire for use in a brazing or soldering operation, the wire comprising:
an elongated body of a metallic material extending along a lengthwise central axis;
a first channel extending lengthwise along the central axis having a first opening formed along a length of the elongated body;
a second channel extending lengthwise along the central axis having a second opening formed along a length of the elongated body, wherein the first and second channels comprise a pair of sidewalls extending lengthwise along the central axis separated by a transverse base, each sidewall extending radially outwardly from the base and forming an angle with the base greater than 90 degrees;
a first volume of a first cured flux solution within the first channel and along at least a portion of the length of the elongated body; and
a second volume of a second cured flux solution within the second channel and along at least a portion of the length of the elongated body, wherein the first and second cured flux solutions are formed by curing a flux solution comprising a polymer-based binder material and a flux material.
2. The wire of claim 1 wherein the first volume of the first flux solution and the second volume of the second flux solution are not equal.
3. The wire of claim 1 wherein a top surface of the first volume of the first flux solution is located below a plane spanning across uppermost points forming the first opening in the first channel.
4. The wire of claim 1 wherein the first flux solution and the second flux solution have different chemistries.
5. The wire of claim 1 wherein the openings in the first and second channels are parallel to the central axis of the wire.
6. The wire of claim 1 wherein the wire forms a ring with the first channel forming at least a portion of a radially inner wall of the ring.
7. The wire of claim 1 wherein the polymer-based binder material comprises a polymer selected from a group consisting of an acrylic polymer and a polymer produced from copolymerization of carbon dioxide.
8. The wire of claim 1 wherein the polymer-based binder material is a poly alkylene carbonate.
9. The wire of claim 1 wherein the flux material is aluminum-based.
10. The wire of claim 1 wherein the flux material is cesium-based.
11. The wire of claim 1 wherein the metallic material of the elongated body is an aluminum alloy.
12. The wire of claim 1 wherein the metallic material is a zinc/aluminum alloy comprising at least 2 percent by weight aluminum.
13. The wire of claim 1 wherein a surface of the first flux solution is exposed through the opening in the first channel.
14. The wire of claim 13 wherein a surface of the second flux solution is exposed through the opening in the second channel.