Brazing (B) and Soldering (S)

 In these processes, the base metals are heated

but do not melt; only the filler metal melts.
 Brazing: filler metals having a melting point above
840° F (450°C)
Heat of brazing removes surface contamination

 Soldering: filler metals have a melting point below

840°F (450°C)
Flux dissolves surface contamination

Soldering and Brazing are actual metal to metal bonds.

Surface tension pulls filler metal into joint. Since
solders have lower melting points than brazing, they
will experience metal creep under tension at lower
temperatures than brazing.
Brazing process
 Brazing metal
 Melts between 450℃ and the melting point of the material being
joined
 Must be capable of flowing through small capillaries, “wetting” the
joint surfaces, and partially alloying with the base metals
 Copper and copper alloys, pure sliver, and aluminum-silicon alloys
are commonly used brazing alloys
 Fluxes
 The functions of fluxes in brazing process
Dissolving oxides that may have formed on the surfaces prior to
heating; preventing he formation of new oxides during heating;
lowering the surface tension between the molten brazing metal
and the surfaces to be joined, thereby promoting the flow of the
molten material into the joint
 Are chemical compounds in which the most common ingredients are
fluorides, chlorides, acids, etc.
 The flux residue should be removed from the work as soon as
brazing is completed
 The strength of a brazed joint and its other properties,
such as gas-tightness and thermal and electrical
conductivities, will depend on the extent to which the
joint gap has been filled by the brazing alloy or, in other
words, on the soundness of the joint.
 The capillary flow depends on the ability of the brazing
alloy to wet the parent metals. This property is
determined by the relative characteristics of the solid and
liquid phases, its measure being the magnitude of the
contact angle, whose meaning is illustrated in the
following figures.
Fig. 1 (a) Spreading of drops of three different liquids with different wetting
properties (i.e., different contact angles, II) on a horizontal solid surface, and (h)
the corresponding~behaviour of these liquids in vertical capillaries
 The lower the contact angle, the better are the wetting and spreading
properties of the brazing alloy, and no capillary flow can take place
unless the contact angle is less than 90~.
 However, even if the conditions favourable for the capillary flow to
take place have been ensured, the soundness of the joint and,
consequently, its strength, will depend on the geometry of the joint
gap. In addition, the load-carrying capacity of a brazed assembly with
100 per cent sound joint may be also affected, partly by the
dimensions of the joint gap and partly by the design of the whole
assembly.
 In many brazing applications, fluxes have to be employed whose
function is to promote wetting and flowing of the brazing alloy by
dissolving nonmetallic (mainly oxide) films, present on the surface of
both the parent metal and brazing alloy. If the joint gap is very small,
the quantity of flux it contains may not be sufficient to dissolve the
surface films or, having dissolved them, its properties (melting point,
viscosity, surface tension) may change in such a manner that it can no
longer be displaced from the joint gap by the advancing brazing alloy.
 Similar considerations apply to brazing in a reducing atmosphere.
 The longer and narrower the joint gap in an assembly brazed in a
reducing atmosphere, the more restricted is the flow of the gases and
the more likely it is that the normally “dry” gas will fail to perform its
function.
 Another factor to consider is the effect of interalloying. In some
instances, the molten brazing alloy will dissolve parent metals to the
extent which depends on the composition of the alloys, on time, and on
temperature. If the metals dissolved in the brazing alloy raise its melting
point, their concentration in the slowly advancing front of the brazing
alloy may increase to such an extent that it may become solid, choke
the joint gap, and stop the flow of the brazing alloy. If the melting point of
the brazing alloy is lowered by the dissolved metals, severe
undercutting or erosion of the parent metals may occur. Either effect is
undesirable. If excessive inter-alloying cannot be prevented by strict
control of the brazing time and temperature, its harmful effect can be
minimized by increasing the joint gap in the former and decreasing it in
the latter instance.
The factors discussed above affect the optimum magnitude of the joint gap
is illustrated by the data reproduced in Table 1, which gives the
recommended joint clearances for various brazing applications.
 Induction-Brazing

Figure 2 Schematic illustration of a continuous

induction-brazing setup for increased productivity.
 Brazing Process Capabilities
 Dissimilar metals can be assembled with good joint strength
 Shear strength of brazed joints can reach 800Mpa

Fig. 3:Joint Designs commonly used in brazing operations.The clearance between the two parts being
brazed is an important factor in joint strength.If the clearance is to small, the molten braze metal will not
fully penetrate the interface.
Good and Poor Brazing Design

Figure 4 Examples of good and poor design for brazing.

Source: American Welding Society.
Fig. 5: Several types of brazed assemblies with their design improving progressively from
left to right. Arrows indicate the direction of the applied load
 Joint Clearance in Brazing

FIGURE 1 When brazing dissimilar metals, the initial joint clearance should be
adjusted for the different thermal expansions (here brass expands more than
steel). Proper brazing clearances should exist at the temperature where the filler
metal flows.
 Common Joint Design

FIGURE 6 The two most common

types of braze joints are butt and lap. Butt offers uniform thickness across
the joint, whereas lap offers greater bonding area and higher strength
 Variations of Butt Joints

FIGURE 7 Variations of the butt and lap configurations include the butt-lap and scarf.
The four types are shown for both flat and tubular parts.
 Common Joint Designs for
Brazing

FIGURE 8 Some common joint designs for assembling parts by brazing.

example Ag brazing of Stainless and Ceramics
An optimum brazed joint can only be achieved if there is close co-
operation between design and production departments.
A series of constructional considerations must be taken into account
before carrying out any brazing work:
First of all the operating conditions (type of load, magnitude of the
load and its direction; media, temperatures) must be established. In
addition, the base material and any heat treatment it is subjected to
must be defined. The brazing alloy and brazing technique are then
selected. The fit of the workpieces must be selected depending on
the brazing technique.

Fits (gap widths)

0 – 0.1 mm Vacuum-brazing, gap-brazing
0 – 0.2 mm Inert gas brazing, gap-brazing
0.05 – 0.2 mm Flux-brazing, gap-brazing by machine
0.05 – 0.5 mm Flux-brazing, manual gap-brazing
> 0.5 Flux-brazing, manual joint-brazing
Brazed joints must be of such a size that they can
be subjected to as high loads as the base
material. The brazed joints are calculated using
the laws of the theory of the strength of materials.
If one assumes there to be predominantly static
loads at room temperature, no major brazing
defects and suitable combinations of materials,
the following can be used for calculating the
brazed joints:
σB Brazed joint ≈ 200 MPa (N/mm2)
τB Brazed joint ≈ 100 MPa (N/mm2)
As a rule of thumb, an overlap length of between
3 and 6 times the sheet thickness can be used
(see Figure )

Figure 9: Examples of overlapped gaps

Unnecessarily large overlap lengths lead to more defects and make „through-
brazing“ more difficult.
Containers – connection pieces – brazed joints
Problem: Due to local heating, the connection pieces become larger in diameter but
the bore not. On cooling the connection piece becomes smaller but the bore not.
Consequence: High stresses in the brazed joint seam with a danger of cracking on
cooling down
Solution: Knock out the container walls or weld on brazed connection pieces.

Figure : Brazing pipes into thick-walled containers

Examples of brazing alloys constructions in brazed
joints:
A selection of technically important examples now follows.
(Favourable gap width range: 0.05 ... 0.2 mm; the gap widths are not shown to
scale in the tables but are enlarged).

Bolts
Pipes
Nipples and flanges
Containers made of sheet metal
Compatibility of Brazing Materials
Brazing Material Families
 Furnace Assembly
If the flux and filler metal can be
preloaded into the joints and the part
can endure uniform heating, a
number of assemblies can be brazed
simultaneously in controlled
atmosphere or vacuum furnaces, a
process known as furnace brazing.

FIGURE 10 Typical furnace-brazed

assemblies.
 Brazing Methods

Torch Brazing:
- Performed by heating the joint
with a torch
- Depositing the filler metal in the
joint
- Suitable part thickness (0.25 –
6.0)mm
- Not a automated process
- More than one torch can be used
in this process FIGURE 11 Schematic of the braze-welding
process.
 Brazing Methods
 Furnace Brazing
 Precleaned & Preloaded with brazing metal
 Heated in a furnace

Fig. 12: An example of furnace brazing a)before b) after

 Other Types Of Brazing

 Induction Brazing

 Resistance Brazing

 Dip Brazing

 Infrared Brazing

 Diffusion Brazing
Brazing filler metals :
A brazing filler metal should meet following
requirements :
1. Sufficient fluidity so the metal will flow evenly
by capillary attraction.
2. Good melting action to form a sound
metallurgical bond.
3. Melting point consistent with the type of metal
to be joined.
Brazing filler metals fall into seven groups : silver,
aluminium-silicon, copper-phosphorus, gold,
copper and copper-zinc, magnesium and nickel.

Teknologi dan Rekayasa

 BRAZING AND BRAZE WELDING

 Fluxes :
Any form of oxide on the surface of a metal will
inhibit a uniform flow of the brazing metals.
Accordingly a flux some kind is necessary to
eliminate the oxide.
The common commercial fluxes are in paste,
liquid, or powder form
Fluxes have as their main ingredient borates,
fused borax, boricacid, fluorides, chlorides, and
fluborates.

Teknologi dan Rekayasa

Advantages
 Joins unweldable materials
 Base metals don’t melt
 Can be used on a wide range of metalic
and ceramics (ideal for dissimilar materials)
 Joined parts can be taken apart at a later
time
 Batch furnace can easily process multiple
parts
 Portable when joining small parts
 Since less heating is required than for
welding, the process can be performed
quickly and economically
 The lower temperatures reduce problems
associated with heat-affected zones and
distortion. Thinner and more complex
assemblies can be joined successfully
 Disadvantages
 Joint tolerance is critical
 Lower strength than a
welded joint
 Large parts require
large furnaces
 Manual processes
require skilled workers
 Flux
Filler metal ring
surrounded by flux
 Question: Is a thin or thick joint
better for tensile strength?
Answer: Thin (contact strengthening)
Tensile Strength

Joint Thickness
Base material Joint – Tri-axial stress
is uniform
 Brazing Techniques
Filler Metal Inserts Pipe

Insert Visual
Poor Joint Inspection

Pipe
Steps:
1) Place insert in groove
2) Fit up pipes
3) Heat joint Good Joint
Thank you!!!