WELCOME

BRAZING
BY
SARATH O M

BRAZING
Brazing is a metal-joining process in which two or more metal
items are joined together by melting and flowing a filler metal into
the joint, the filler metal having a lower melting point than the
adjoining metal.
Brazing differs from welding in that it does not involve melting the
work pieces.
Brazing is similar to soldering, except the temperatures used to
melt the filler metal are higher for brazing.

 The filler metal flows into the gap

between close-fitting parts
The filler metal is brought slightly
above its melting temperature while
protected by a suitable atmosphere,
usually a flux.
It then flows over the base metal
(known as wetting) and is then cooled
to join the work pieces together.

FILLER MATERIALS
A variety of alloys are used as filler metals for brazing
depending on the intended use or application method. In
general, braze alloys are made up of 3 or more metals to
form an alloy with the desired properties.
Aluminum-silicon ,Copper ,Copper-silver , Copper-zinc
(brass),Copper-tin (bronze)

Flux
Flux is required to prevent oxides from forming while the metal is heated.
The flux also serves the purpose of cleaning any contamination left on
the brazing surfaces.
Flux can be applied in any number of forms including flux paste, liquid,
powder or pre-made brazing pastes that combine flux with filler metal
powder.
Phosphorus-containing brazing alloys can be self-fluxing when joining
copper to copper
Excess flux should be removed when the cycle is completed because
flux left in the joint can lead to corrosion, impede joint inspection, and
prevent further surface finishing operations.

ATMOSPHERE

As brazing work requires high temperatures, oxidation of the metal surface occurs in an
oxygen-containing atmosphere. This may necessitate the use of an atmospheric
environment other than air.
Combusted fuel gas (low hydrogen, AWS type 1, "exothermic generated atmospheres"):
87% N2, 1112% CO2, 5-1% CO, 5-1% H2.
For silver, copper-phosphorus and copper-zinc filler metals. For brazing copper and brass.
Combusted fuel gas (decarburizing, AWS type 2, "endothermic generated atmospheres"):
7071% N2, 56% CO2, 910% CO, 1415% H2. For copper, silver, copper-phosphorus and
copper-zinc filler metals.
For brazing copper, brass, nickel alloys, Monel, medium carbon steels.

TYPES
Torch brazing
Furnace brazing
Induction brazing
Dip brazing
Resistance brazing
Infrared brazing
Blanket brazing
Electron beam and laser brazing
Braze welding

TORCH BRAZING

In torch brazing, the heating of the joint is accomplished using the

flame of a single or multiple gas torches. Multiple torches are used
to obtain a uniform heating throughout the joint area.
The brazing filler metal may be preplaced at the joint in the form of
rings, washers, strips, slugs, powder, or it may be fed manually.
Torch brazing is very useful on assemblies that involve heating
sections of different mass.
Manual torch brazing is particularly useful for repair work.

FURNACE BRAZING

In furnace brazing, the parent materials / parts are cleaned and

placed in a furnace.

 The parts should be self-jigging and assembled, with the filler

materials already placed near or in the joint.
The brazing filler material may be in the form of wire, foil,
fillings, slugs, powder, paste, tape, and so on.
The furnaces are usually of electrical resistance type.
Furnace brazing is also performed in vacuum during the
fabrication of aerospace and nuclear components where
entrapped fluxes are not tolerable.

Dip brazing

Dip brazing is accomplished by immersing clean and assembled parts

into a molten bath contained in a suitable pot.

 Dip brazing is classified into chemical bath dip brazing and molten
metal bath dip brazing.
In chemical bath dip brazing the filler metal, in a suitable form, is
preplaced and the assembly is dipped in a bath of molten salt. The salt
bath provides the required heat and necessary protection from
oxidation.
Dip brazing is preferred for brazing small to medium sized parts with
multiple or hidden joints. It is also useful to braze parts of irregular
shapes.

ADVANTAGES
A major advantage of brazing is the ability to join the same or
different metals with considerable strength
Brazing does not melt the base metal of the joint
It allows much tighter control over tolerances
Produces a clean joint without the need for secondary finishing.
Brazing also produces less thermal distortion than welding due to
the uniform heating of a brazed piece.
Complex and multi-part assemblies can be brazed costeffectively.

DISADVANTAGES
Lack of joint strength as compared to a welded joint due to the softer
filler metals used
Brazed joints can be damaged under high service temperatures.
Brazed joints require a high degree of base-metal cleanliness when
done in an industrial setting.
Some brazing applications require the use of adequate fluxing
agents to control cleanliness.
The joint color is often different from that of the base metal, creating
an aesthetic disadvantage.

THANK YOU