Polytechnic University of the

Philippines
College Of Engineering
Mechanical Engineering Department

WORKSHOP THEORY AND PRACTICE

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BRAZING
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Reporters:
FANOGA, DENNIS DALE A.
GADIL, WILKENS R.
RICAFORT. HARRIS R.

Submitted To:
ENGR. CHARLES G. GAGUI
 BRAZING AND BRAZE WELDING: DIFFERENTIATION, DEFINITION
AND BACKGROUND

Brazing is a metal-joining process whereby a filler metal is heated above and distributed

between two or more close-fitting parts by capillary action. The filler metal is brought slightly

above its melting (liquidus) 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. Brazing is a process which differs from braze welding in one very important way: In

brazing, the filler metal is drawn into the joint by capillary attraction, rather than deposited in the

joint in somewhat the same fashion as in oxy-acetylene fusion welding. While the majority of

industrial brazing operations do not involve the oxy-acetylene fusion welding, in one field – the

fabrication and installation of copper-tube piping systems – the oxy-acetylene torch is frequently

employed. We shall cover this application shortly. First, let’s take a general look at brazing, an

extremely important process in metal fabrication. By American Welding Society definition,

brazing is a welding process in which the filler metal has a melting point higher than 8000F

(4250C) but lower than that of the metal of metals being joined, and in which the filler metal is

drawn into the joint by capillary attraction. What do we mean by”capillary attraction”? To put it

in very simple terms, it is the ability of a liquid to rise into a narrow gap or passage against the

force of gravity. You can demonstrate capillary attraction with two thin pieces of clean glass, as

shown in Fig. 19-1. Or you can use two short pieces of glass tubing, one with a very small

diameter bore (1 mm or less) one with an inside diameter of 5-6 mm. The water will rise

appreciably in the smaller tube, little in the larger tube. (Not all liquids behave in this fashion;

many different factors are involved. With mercury, for example, the level in a small diameter
tube inserted into a pool of the liquid will actually fall below the level of the pool surface.)The

process known as soldering is generally similar to brazing except that the filler metals used melt

at temperatures below 4270C (8000F). In actual practice, most brazing alloys melt at temperatures

well above4270C, most solders at temperatures well below 4270C. Many of the brazing alloys

based on silver (all of which melt above 6000C) were formerly termed”silver solders”. Avoid that

term, and its relative,”silver soldering”. Even the term ”silver brazing” is sometimes misleading,

since some brazing applications for which silver alloys are generally used can also be handled

with alloys which contain no silver.

welding outfit. It closely resembles fusion welding in several important respects. It is used to

produce joints of excellent strength in steel, in cast iron, and in copper and some copper alloys.

However, in braze welding, the filler metal always has a melting point well below the melting

point of the base metal, and the base metal is never melted. Years ago, the process we now term”

braze welding” was commonly known as”bronze-welding”. Ever since the process was

renamed”braze welding”, there has existed a degree of confusion between the terms”brazing”

and” braze welding”. The American Welding Society definitions for ”brazing” and ”braze

welding” both stipulate that the filler metal must have a melting point above 4250C (8000F).

However, the definitions state that in brazing the filler metal is drawn into a tight-fitting joint

by  capillary attraction; in  braze welding the filler metal is deposited in the joint by other than

capillary attraction. We shall talk about the use of the flame in brazing operations in another

chapter. The basis for the braze welding process is that both brass and bronze* will flow onto

properly prepared surfaces of higher-melting-point metals or alloys to form a bond or molecular

union which has excellent strength. The base metal is never melted. It is merely raised to the

temperature at which the filler metal will tin  – form a smooth film –on the surface of the joint.

Although the temperatures involved are much lower than those required for the fusion welding of

steel, braze welding is primarily an oxy-acetylene process. The intense heat of the oxy-acetylene

flame quickly raises the base metal to the proper temperature for tinning. The welder can control

every variable factor involved: the temperature of the base metal, the melting of the filler rod,

and the condition (neutral or slightly oxidizing) of the flame.

TYPES OF BRASS FILLER WIRES

addition, by which they are known. The most common is silicon brass, the others being

manganese, nickel and aluminum.

Silicon

When metals are cast directly into their finished shape silicon addition improves fluidity, and

refines the crystalline structure, making the grains small and hence stronger. Silicon strengthens

brass and aids capillary action, so it is a good general purpose wire.

Manganese

This is designed particularly for the joining of cast iron and has good strength/bonding

characteristics with this metal.

Nickel

Nickel imparts high strength but it is the most expensive alloy addition. Typical applications are

attaching tool steel tips to machine cutting tools and joining stainless steel.

Aluminum

Aluminum filler is only used for the joining or repair of aluminum bronzes.

Aluminum Alloys

The term “brazing” implies the use of brass wire, but in fact simply describes capillary joints

made above 500 degree Celsius, with lower temperature ones being made by soldering.

Aluminum can be brazed with an aluminum wire, typically with silicon or silicon/copper

additions, which melt a little below the melting point of pure aluminum.

TYPES OF FLUX
 A general purpose borax-based flux obtained in powder form is used with brass filler

wires. The exception is aluminum bronze, which requires a unique flux. Proprietary fluxes are

available for a range of applications and are available not interchangeable-an aluminum brazing

flux is not suitable for fusion welding or vice versa.

Wire with solid flux coatings or with flux embedded in a serrated surface may be

preferred because they are enable the joint to be made without interruption.

HEAT SOURCE

A blowtorch may provide enough heat to braze smaller items but an oxy-acetylene flame

is faster and can be used to braze weld. Brazing requires a neutral heat source but for braze

welding a slightly oxidizing one is necessary to prevent zinc loss. When joining brass or working

on a brass surface on a multi-run joint, the process becomes one of fusion welding and requires a

increasingly oxidizing flame. Lack of oxygen in the flame is indicated by a honeycombed,

porous weld.

BRAZING TECHNIQUE

The joint is prefluxed by mixing a little flux with water or ideally alcohol and painting it

on the joint surfaces.

If possible the entire joint is heated uniformly, rather than locally as in welding, until the

flux melts and turns liquid. Following a little further heating , filler is brought into contact with a

joint, and if the temperature is sufficient it flows along and through the entire joint.

BRAZE WELDING TECHNIQUE

wire is heated and dipped in the flux; a tuft will stick to the end heated surface initially flux

transfer, and when hot enough the wire end melts and transfer too. If the joint is too cold wetting

will not occur. If it is too hot then zinc oxide in the form of white fume burns off the weld. Not

only is the weld depleted of zinc and the strength this imparts, but the zinc oxide fume are also

very harmful when inhaled, producing zinc ague which has flu-like symptoms of shivering and

aching.

To apply brass wires successfully:

1. The metal must be clean.

2. The surfaces must coat with flux before they oxidize.

3. Appropriate wire must be used.

4. The joint must be hot enough to melt the wire.

5. Enough wire must be added.

After braze welding the residual flux forms in hard, opaque islands on the welds surface and is

corrosive. It can be chipped off wearing suitable eye protection.

ADVANTAGES AND DISADVANTAGES

Brazing has many advantages over other metal-joining techniques, such as welding.

Since brazing does not melt the base metal of the joint, it allows much tighter control over

tolerances and produces a clean join without the need for secondary finishing. Additionally,

dissimilar metals and non-metals (i.e. metalized ceramics) can be brazed. In general, 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 cost-effectively. Another advantage is that the

brazing can be coated or clad for protective purposes. Finally, brazing is easily adapted to mass

production and it is easy to automate because the individual process parameters are less sensitive

to variation.

One of the main disadvantages is: the lack of joint strength as compared to a welded joint

due to the softer filler metals used.  The strength of the brazed joint is likely to be less than that

of the base metal(s) but greater than the filler metal. Another disadvantage is that 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 than that of the

base metal, creating an aesthetic disadvantage.