SOLDERING AND BRAZING

ME 473 WELDING TECHNOLOGY

Yrd.Do.Dr. Yrd.Do.Dr . OUZHAN YILMAZ

Department of Mechanical Engineering

The University of Gaziantep

Welding Technology

Brazing: Introduction
Brazing is a liquid phase process, whereby molten filler metal (the braze) is drawn into the gap between closely adjacent surfaces by capillary attraction In general, the melting point of the filler metal is above 450 C, but always below that of the parent material. To achieve a perfect joint, the filler and parent materials should be metallurgically compatible and the design of the joint should incorporate a gap into which the braze filler metal will be drawn. There are many ways of brazing, and they all include the method of applying heat:
Dip brazing Furnace brazing Induction brazing Infrared brazing Resistance brazing Torch brazing Others
Dr. Ouzhan Ylmaz

The processes can be carried out under vacuum, inert gas or by using fluxes.

Welding Technology

Brazing: Methods
Furnace Brazing:
This process is accomplished by placing cleaned parts in a furnace. The parts should be self-jigging and assembled, with filler materials preplaced near or in the joint. The preplaced brazing filler material may be in the form of wire, foil, fillings, slugs, powder, paste, tape, and so on. The furnaces are usually heated by electrical resistance. Automatic temperature controllers are required so that they can be programmed for the brazing temperatures and cooling. Flux is employed except when an atmosphere is specifically introduced in the furnace to perform this function. Flux should not be used where postbrazed cleaning is made difficult by the complexity of the design of the brazed parts. Furnace brazing is often done without the use of flux by the use of special atmospheres (hydrogen and other special gases helium and argon-) in the brazing furnace.

Furnace Brazing Dr. Ouzhan Ylmaz

Welding Technology

Brazing: Methods
Resistance Brazing:
The heat is obtained from the resistance to the flow of an electrical current through the parts being brazed. The parts become a part of the electrical circuit through electrodes made of copper alloys or carbon-graphite. Alternating current is normally applied. The parts to be brazed are held betwen the two electrodes while the correct pressure and electrical current applied. The pressure is maintained until the filler metal has solidified. Resistance brazing is normally used for lowvolume production where heating is localized at the area to be brazed. It is also limitted to applications where the brazing filler metal is preplaced.

Dr. Ouzhan Ylmaz

Welding Technology

Brazing: Methods
Torch Brazing:
It is done by heating the parts to be brazed with the flame of a gas torch or torches. The temperature and the amount of heat required determine the gas used. Torch brazing is very useful on assemblies that involve heating sections of different mass. Manual torch brazing is particularly useful for repair work. The neutral or reduced flame is normally used. The brazing filler metal may be preplaced in or it may be face-fed manually. Torch brazing is used when the part to be brazed is too large, is an unusual shape, or cannot be heated by the other methods.

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Welding Technology

Brazing: Filler metals

Filler Metals:
Aluminium-silicon, copper, copper-zinc, copped-phosphorus, nickel-gold, heat-resisting materials, magnesium, and silver. Filler metals are available in many forms; the most common is the wire and rod. They are also available in thin sheet, powder, paste, or as a clad surface of the part to be brazed. Base metal and the compatible filler metal:

Base Metal
Aluminium Nickel-Copper alloys Copper Steel and cast iron Stainless steel

Filler Metal
Aluminium and Silicon Copper Copper and phosphorus Copper and zinc Gold and silver

Dr. Ouzhan Ylmaz

Welding Technology

Brazing: Fluxes
Fluxes: The flux is chosen according to the material to be brazed and the temperature range. Flux in powder form is usually used for furnace brazing. Paste flux is usually used for torch brazing. Placement of the flux affects the quality of the brazed joint. Functions:
Remove oxides from the surface chemically Avoid oxidation during preheat Helps to decrease the surface tension of the molten filler metal so that it can flow and spread over the surface easily Reduce the cooling time

Uses: Three major industries using brazing are the electrical industry, the utensilmanufacturing industry and the maintenance and repair industry

Dr. Ouzhan Ylmaz

Welding Technology

Brazing: Applications

Dr. Ouzhan Ylmaz

Welding Technology

Brazing: Applications

Dr. Ouzhan Ylmaz

Welding Technology

Brazing: Applications

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Dr. Ouzhan Ylmaz

Welding Technology

Brazing: Quality
It is important to have extremely clean surfaces for the brazed joint. Mechanical surface preparations such as grinding, sandblasting, wire brushing, filing, and machining can be used. The surface must be clean and removed from dust, oil, etc. Throubleshooting hints: If the brazing filler metal does not wet the surface:
Increase the amount of flux used Roughen the surface Change the work position so that the gravity will help the filler metal fill the joint

If the brazing alloy does not flow through the joint

Allow more time for heating Heat to a higher temp Apply flux both the base metal and brazing filler metal.

If the brazing filler metal melts but does not flow

Coat the filler metal with flux Mechanically and chemically clean the filler metal if there are surface oxides present.

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Welding Technology

Soldering: Introduction
Soldering is a group of processes that produce coalescence of material by heating them to the soldering temperature and by using a filler metal having liquidus not exceeding 450C and below the solidus of the base metals. The filler metal is distributed between closely fitted fying surfaces of the workpieces. Solder is a filler metal used in soldering that has liquidus not exceeding 450C. It is normally a nonferrous alloy. There are at least eight popular soldering methods in wide use:
Dip soldering Furnace soldering Induction soldering Infrared soldering Iron soldering Resistance soldering Torch soldering Wave soldering etc.

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Dr. Ouzhan Ylmaz

Welding Technology

Soldering: Methods
Furnace Soldering: It is a soldering process in which the parts to be joined are placed in a furnace and heated to the soldering temperature. In furnace soldering the parts must be assembled and fixed in their proper position. The solder must be preplaced in the joint. Resistance Soldering: It is soldering process that uses heat from the resistance to the electric current flow in a circuit of which the workpieces are a part. This is a very common method of manufacturing electrical machinery involving soldered joints The solder is applied manually and also used for soldering copper plumbing fittings.
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Welding Technology

Soldering: Methods
Torch Soldering: It is very similar to torch brazing except that lower temperatures are involved and air is used rather than oxygen. The solder is manually applied. Torch soldering is widely used in the plumbing trade for soldering copper tubing to copper fittings. Soldering flux: The flux helps to remove oxide, but the flux must be designed so that it can be removed after the joints in soldered. It should be fluid at a lower temp than the liquidus of the solder It should have a lower specific gravity than the solder so that the solder will displace it in the joint. Flux should be applied to the base metal to protect it from oxidation.
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Welding Technology

Soldering: Flux & Solder

Solder
Solders are classified acccording to whether or not they contain lead. The most common general-purpose solder is the 50% lead- 50% tin composition.

Solder procedure:
The joint must be properly cleaned. It must be free of all oil, grease, dirt, oxides, and so on. Cleaning can be accomplished by brushing, filling, machining, sanding, and by the use of chemicals. Heat is applied to the joint by many different mechanism and then the space is filled with solder.

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Welding Technology

Soldering: Applications

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Welding Technology

Soldering: Applications

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Dr. Ouzhan Ylmaz

End of the chapter.

Thank you

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