Welding, Soldering & Brazing

WELDING
Welding
Process by which two pieces of similar metals are joined
together without the addition of another metal.
INDICATIONS
• In orthodontics, to join flat structures like bands and brackets
• In pedodontics, to join bands and other appliances
• In prosthodontics, to join wrought wire clasp and repair of
broken metal partial dentures.

Cold Types of Hot

welding welding welding
 Types of welding
Cold welding Hot welding
 No heat is used. It  Heat of enough
can be done by intensity is used to
hammering or melt the metals being
pressure. joined .
 for example.  Heat source can be
gold foil filling. oxyacetylene flame
or high amperage
electric current.
Avantages
1. Easy to use
2. Not technique sensitive
3. Solder or flux not needed
4. Ideal for joining flat surfaces
5. Produce less chances of joint failure
6. Produce strong joint
7. Not much heat is generated.
 Principle of orthodontinc welding

 Heat generated due to electrical

resistance,causes metals to
momentarily melt and fuse.
 Weld nugget/Spot weld
Due to heat generated by the current
and the pressure from the electrode, the
metals melt and fuse together resulting in
a joint called weld nugget or spot weld.
 Steps in welding
 Apparatus – Orthodontic spot welder
 Clean the parts to be joined.

 Check the surface of electrodes, should be evenly in contact with each

other to avoid sparking and localised welding.

 Adjust welder setting as recommended by manufacturer

 Broad electrode for thin material and narrow for thicker for even
distribution of weld nugget (the spot where the parts are joined
together). Insert the weld (parts to be joined) b/w the electrode press the
switch to allow large current

 Combination of heat and pressure will join the metal piece together .
 Soldering
Soldering is a process where 2 or more metals are joined together by
melting and flowing a filler metal (solder) into the joint. It is of 2 types:

Soft soldering Hard soldering

 Melting temp of filler metal  Melting temp of filler

(solder) below 350 degree
Celsius. below 450 degree Celsius.
 Lead-tin alloy is used as filler  Require a heat source like
material.
 Does not need a heat source
gas torch.
like gas torch can be melted  Suitable for use in dentistry
with electric gun/ iron.
 Unsuitable for dentistry as joint is
as joint is strong.
weak and very low load
bearing capacity.
 The lead used is hazardous to
health.
 Brazing

 Joining of metal surfaces by use of filler metal having

melting temp more than 450 degree Celsius.
 Provides strongest joint also require highest temp source
like carbon arch torch.
 Most dental procedures use temperatures in the range of
600-750° C. So, technically they should be called
brazing. However, the technique used is more like hard
soldering. So the terms are used interchangeably in
dentistry.
Components of a soldered
joint
Parent
metal
Heat
source
Filler
metal/
solder
Flux
Parent metal

 Metal or alloy
 Also known as substrate metal.
 Different parent metal have different melting
points, wettability and oxide formation.
 Thus, solder and the flux have to be chosen
accordingly.
 The most common parent/ substrate metals in
orthodontics are stainless steel, beta titanium and
cobalt-chrome.
Filler metal/solder
 Alloy of two or more metal
used for joining other metal
together by creating a strong
intermetallic bond between
itself and the parent metal
 Qualities of an ideal solder
1. Should melt at lower temp. (at
least 55.6ºC) than the parent
metal.
2. Should have sufficient fluidity
3. Should have ability to wet.
4. Good resistance to corrosion.
5. Acceptable color to produce
an inconspicous joint
Classification of solder

Base on melting range of alloy

1.Soft solder
2.Hard solder
3.Very hard/brazing solder
Based on type of metal
1.Precious metal solder
2.Nonprecious metal solder
 Soft solders

Lead tin eutectic alloys in a ratio of 40: 60.

Also known as Plumber’s solder
Low melting range (260° C or less)
Can be melted using routine electric gun
Lack corrosion resistance, produce weak joints,
not suitable for dental use.
Other soft solders are: tin-zinc, cadmium-silver,
zinc-aluminum, tin-silver.
 Hard solders
Greater hardness, possess better strength.
Higher melting temperatures.
Gas torch or similar device is used to generate heat.
2 types of hard solders: gold & silver solders

 Gold solders composition

1. Gold-45-81%
• These have high melting
2. Silver 8-30% temperature range of 750-
900° C
3. Copper 7-20%
• Good tarnish and corrosion
4. Tin –traces resistance and so are
5. Zinc-traces extensively used for crown
and bridge applications
6. Phosphorous -traces
 Hard solders

 Silver solders composition

• The formation of silver copper eutectic
1. Silver 10-80% is responsible for low melting range
2. Copper 15-30 % (600-750 C) of silver solder.
• Resistance to tarnish and corrosion not
3. Zinc- 4-35 % good as silver solders
4. Tin –traces • Strength comparable to gold solders.
5. Phosphorous -traces
 Flux
 Compound applied to metal surface to be joint to
prevent formation of oxide that may reduce the
strength of soldered area.

Functions of flux:
1. Eliminates impurities by dissolving any oxide
present and carries them away from the
joint (Solvent) .
2. Reduces any oxides present and exposes
the clean surface (Reducing agent).
3. Covers the metal surface and prevents
access to oxygen so that no oxides can
form. (Surface protection type)
4. Acts as a wetting agent and reduces the
surface tension.

* Presence of oxide layer prevents the flow of solder on the parent metal.
 Classification of fluxes
According to their purpose
1. Surface protection type
2. Reducing agent type.
3. Reducing solvent type.
 Acc. to their pH
1. Acidic flux . Eg . SiO2.
2. Basic flux. Eg.CaO(lime).
3. Neutral flux. Eg.borax
 Acc to their source
1. Organic eg. Rosin flux
2. Inorganic eg.halogenides
 Acc to their composition
1. Borax flux: Used for noble metal alloys
2. Flouride flux: Used for base metal alloys
1. Borax flux:
 Used for noble metal alloys.
 Based on boric or borate compounds such as boric acid and boric anhydrate.
 Act as protective and reducing fluxes.
2. Flouride flux:
 Used for base metal alloys.
 Act as protective, reducing and solvent fluxes.

 Flux may be used by painting it on the substrate metal at the junction of pieces to be joined.
 Minimal amount of flux should be used. Otherwise it may lead to weakening of the joint and
discoloration.

 Antiflux material used to restrict the flow of solder into unwanted areas eg. Graphite,
whiting(calcium carbonate in alcohol), rouge.
 Heat sources

 Gas air torch

 High frequency AC current
 Laser Infrared source
 Hydrogen and oxygen combustion

HYDROFLAME SOLDERING UNIT

Gas air or Gas-Oxygen torch

 Hydrogen, natural gas, acetylene and propane can be

used as fuel
 Properties
 Colourless
 Easily liquifiable
 Uniform in quality
 Readily available
 Gives a clean flame Gas air torch
Flame
Steps in soldering
 Cleaning and assembling
 Maintaining a proper gap in between the
surface (If gap is too narrow strength is
compromised by inclusion of flux or porosities,
If gap is too great, joint strength will be
controlled by the strength of the filler).
 Applying a suitable flux.
 Applying heat to the parts being joined.
 Solder has to be heated till it is cherry red.
 Steps

Assembly of Applying solder

parent metal Applying flux

Heating the solder Soldered joint