COLEGIO DE SAN JUAN DE LETRAN

SCHOOL OF ENGINEERING
S.Y. 2020

ME001L- WORKSHOP THEORY AND PRACTICE

LABORATORY
RESEARCH WORK NO.3

AYSON, JONATHAN N. #2
1ME1
DATE SUBMITTED: MAY 6, 2020

ENGR. ROBERT MONTALES

INSTRUCTOR
Module 4 : Brazing

A) Research Work:

1. What is Brazing?

Brazing joins material by heating it in the presence of a filler metal having a melting point
above 840°F (450°C) but below the solidification temperature of the base metal. A variety of
processes can provide the heat required for brazing. The filler metal used distributes itself between
the closely fitted surfaces of the joint by capillary action. Parts must be properly cleaned in order to
achieve a good quality joint. To prevent excessive oxidation during brazing, the parts must be
protected by either flux or atmosphere during the heating process. The parts must be designed to
provide a capillary for the filler metal when properly aligned, and a heating process must be selected
to provide the proper brazing temperature and heat distribution.

Ideal for joining dissimilar metals, brazing is a commercially accepted process used in a wide
range of industries due to its flexibility and the high integrity to which joints may be produced. This
makes it reliable in critical and non-critical applications, and it is one of the most widely used joining
methods.

2. What is the working principle of brazing?

 ‘Solidus’, ‘Liquidus’ and ‘Melting Range’

The temperature at which a brazing alloy can be used to produce a joint must be
higher than that at which the alloy becomes molten. Thus, the melting point of an alloy is of
primary importance. In most cases, brazing alloys do not have a single melting point, but
melt over a given temperature range. The temperature at which the alloy begins to melt is
called the ‘solidus’, and the temperature at which the alloy becomes fully molten is called
the ‘liquidus’. The temperature interval between the solidus and the liquidus temperatures
is called ‘the melting range’ of the alloy.

 Working temperature

As already mentioned, once a brazing material is heated to its solidus temperature,

it begins to melt. As the temperature is gradually increased, more of the alloy becomes
 molten until, at the liquidus temperature, the alloy is 100% liquid. Thus, throughout the
melting range of the alloy, the relative proportion of the liquid phase to the solid phase
increases as the temperature rises. To produce a brazed joint, the brazing alloy must be
sufficiently fluid to be drawn into a capillary gap. With most alloys, this point of ‘sufficient
fluidity’ is reached at a temperature which is above the solidus of the alloy, but below the
liquidus. This temperature is known as the ‘working temperature’ of the brazing alloy.
Probably the best known example of working temperature is provided by the Phos series of
alloys produced by Thessco Limited. Here, the solidus is about 645°C, and the true liquidus
in the region of 800°C, but dependent on the composition of the alloy, the working
temperature can be a low as 700°C. This means that the material is sufficiently fluid at that
temperature to permit normal capillary flow to occur.

 Capillary attraction
It is fundamental to the brazing process that the brazing material is drawn by
capillary attraction into the joint; this progressively displaces flux, gases etc. and ensures
maximum joint soundness. The physics of capillary attraction are quite complex, but it can
be summarised as: ‘The capillary flow of a molten brazing alloy is dependent on the ability of
that alloy to ‘wet’ the parent metals to be joined’. Many factors influence the wettability of
a brazing alloy onto the parent metals to be joined, but probably the most important of
these is surface cleanliness. Not only should surfaces be free from contaminants as
assembled, but must also be maintained in this condition (at least in the immediate joint
area) until flow of the brazing alloy is completed. This is achieved by the use of a suitable
protective environment whether it be an inert or reducing gaseous envelope, or more
commonly, an active flux layer.
 Liquidation

The fact that the majority of filler materials used in brazing do not have a single
melting point can be a source of trouble. This is particularly true of those brazing alloys
which have a long solidus-liquidus interval (in excess of 70°C for example), and where it is
desired to use these materials as pre-forms for the joining of relatively large parts. In these
conditions, it is Thessco: Brazing Principles Page 2 clear that the time taken to heat the
brazing alloy from its solidus to its liquidus temperature will be long, and it is this factor
which may give rise to concerns. When silver brazing alloys begin to melt, the first parts to
 become molten are relatively richer in silver, zinc and cadmium than the starting material.
This results in the remaining solid portion being relatively richer in copper. If this alloy is in
contact with the mouth of a capillary joint, the liquid will be drawn into the gap and the
solid portion, denuded of its low melting point constituents, will no longer have the liquidus
temperature of the starting material. This phenomenon is known as liquation. In order to
cause the remaining solid portion to melt, it must be heated to a much higher temperature
than the original liquidus of the alloys being used. Consequently, in any brazing operation
where a slow heating rate is likely to be encountered (in furnace brazing or where the parts
have a high thermal mass, for example), it is necessary for alloys with short ranges to be
used.

3. How would you differentiate Brazing from Welding? Which one is better?
 In brazing, the filler metal has a lower melting point than the adjoining metal. In welding,
the filler metal has a higher melting point, like soldering.
 In brazing, fabricators don’t melt the base metal. In welding, fabricators melt the base metal
and each workpiece together.
 Brazing uses capillary action, and welding uses fusion.

Brazing filler materials come in a wide range of compositions, shapes, and sizes to suit most
applications. Compared with welding, brazing requires relatively low temperatures, is readily
automated, and can join dissimilar metals. Brazing's ability to join dissimilar metals lets users select
metals best suited for an application's functional requirements, regardless of differences in melting
temperatures. razing typically produces a tiny, neat fillet, versus the irregular bead of a welded joint.
This is especially important on consumer products-where appearance is critical. Brazed joints can almost
always be used as is, without additional finishing operations. For instance, brazing is the better option
on a T-joint with 0.005-in. sheet metal bonded to 0.5-in. stock. The intense heat of welding will likely
burn through, or at least warp, the thin section. Brazing's broader heating and lower temperature joins
the sections without distortion. Brazing temperatures are lower, generally 1,150 to 1,600°F, most
physical properties remain unaffected. Distortion and warping are minimal, and it minimizes stresses in
the joint area. Lower temperatures also require less energy, which can result in significant cost savings.

4. What do you need to consider to have a good brazing process?

 Ensure good fit and proper clearances.

Brazing uses capillary action to distribute molten filler metal between the surfaces of the
base metals. So when you're brazing, maintain a clearance between the base metals to allow
capillary action to work most effectively. In almost all cases, this means a close clearance.
Optimal clearance or joint gap for most filler metals is 0.0015 inch, but typical clearances range
from 0.001 to 0.005 in.

In everyday brazing, clearances don't have to be overly precise to obtain a sufficiently

strong joint. Capillary action operates over a range of clearances, so you have a certain amount
of leeway. In everyday shop practice, an easy slip fit typically will produce an adequate brazed
joint between two tubular parts. Keep in mind that generally, as the clearance increases, joint
strength decreases. Capillary action stops around 0.012 in. If you're joining two flat parts, you
can rest one on top of the other. The metal-to-metal contact is all the clearance you'll usually
need, because the average mill finish of metals provides enough surface roughness to create
capillary paths for the flow of molten filler metal. Highly polished surfaces, on the other hand,
tend to restrict filler metal flow.

When you're planning your joint clearances, remember that brazed joints are made at
brazing temperatures, not at room temperature. Take into account the coefficient of thermal
expansion of the metals being joined, particularly with tubular assemblies in which dissimilar
metals are joined.

 Clean the metals.

Capillary action works properly only with clean metal surfaces. If they're coated with oil,
grease, rust, scale, or dirt, you must remove these contaminants or they'll form a barrier
between the base metal surfaces and the brazing materials.

Cleaning metal parts seldom is complicated, but you have to do it in the right sequence.
Oil and grease should be removed first, because an acid pickle solution aimed to remove rust
and scale won't work on a greasy surface. Start by getting rid of oil and grease. In most cases
you can do this either by dipping the parts into a suitable degreasing solvent, by vapor
degreasing, or by alkaline or aqueous cleaning. If the metal surfaces are coated with oxide or
scale, you can remove those contaminants chemically or mechanically. For chemical removal,
 use an acid pickle treatment. Make sure that the chemicals are compatible with the base metals
being cleaned and that no acid traces remain in crevices or blind holes. Mechanical removal calls
for abrasive cleaning.

Particularly in repair brazing, where parts may be very dirty or heavily rusted, you can
speed the cleaning process by using an emery cloth, grinding wheel, or file or grit blast, followed
by a rinsing operation. Once the parts are thoroughly clean, flux and braze them as soon as
possible to reduce the chance for recontamination of surfaces by factory dust or body oils
deposited through handling. Note that certain cleaning mediums will leave a residue and embed
in the surface, making it unwettable.

 Flux the parts.

Flux is a chemical compound applied to the joint surfaces before brazing. Its use, with a
few exceptions, is essential in the atmospheric brazing process. This is because heating a metal
surface accelerates oxide formation, the result of a chemical reaction between the hot metal
and oxygen in the air. If you don't prevent these oxides from forming, they'll inhibit the brazing
filler metal from wetting and bonding to the surfaces.

A coating of flux on the joint area shields the surfaces from the air, preventing oxide
formation. It also dissolves and absorbs any oxides that form during heating or that were not
removed completely in the cleaning process.

You can apply flux in any way to the joint as long as you cover the joint surfaces
completely. Flux conventionally is made in a paste, so it's usually most convenient to brush it on.
But as production quantities increase, it may be more efficient to apply the flux by dipping:
dispensing a premeasured deposit of high-viscosity flux from an applicator gun.

Typically, you apply flux just before brazing if possible so it has the least amount of time
to dry out and flake off or get knocked off the parts in handling. Choose a flux that's formulated
for the specific metals, temperatures, and conditions of your brazing application.

5. As a mechanical engineering student, why is it important for you to learn about brazing?
As a mechanical engineering student, it is important for me to learn about brazing because it has
many applications mainly to automotive and industrial machines. It will help me to understand
on how the products or machines are made by using this process. Without the process of
 brazing, the metals will not be joined together to make different machines and products that are
useful for the people. Brazing is useful for me in the future if I am going to design parts of a
machine because without brazing, my design would not be possible.
6. Of the many safety precautions in brazing, what would you consider as the top
three most important? Justify your answers.
 Wear appropriate personal protection equipment
It includes gloves to protect hands against heat and shaded goggles or fixed glass
shields. It will help to protect operators against eye fatigue and vision damage.
 Ventilate confined areas.

Brazing involves the possibility of dangerous fumes and gases rising from base metal
coatings, zinc and cadmium-bearing filler metals, as well as fluorides in fluxes. Use ventilating
fans and exhaust hoods to carry all fumes and gases away from work, along with air-supplied
respirators as required.

 Heat metals broadly.

It’s important to heat the base metals broadly and uniformly. Why? Intense, localized
heating consumes flux, increasing the danger of fuming. Apply heat only to the base metals, not
to the filler metal, because direct heating of the filler metal causes overheating and fuming.

7. What are the important applications of brazing?

 Domestic & industrial cooling and heat exchangers

Brazing alloys for producing engine radiators, domestic and industrial refrigerators, heat
exchangers, air conditioners, water heaters and boilers, electrical appliances, electrical coils,
condensers, evaporators.

 Electromechanical systems

These alloys are suitable for all electrical systems, power generators, transformers,
electrical motors, armoured heating elements, electrical contacts, breakers, relays.

 Automotive

Alloys for automotive applications accompanied by PPAP documentation.

  Solar panels

The brazing alloys used for producing solar panels.

 Measuring and calibration instruments

Alloys for producing thermostats, pressure switches, pressure gauges, hygrometers.

 Tubular solutions

For constructing metal furniture, bicycle frames, mopeds, motorcycles.

 Silverware and jewellery

Metal frames, buckles, zippers, fasteners for handbags, metallic buttons, trinkets,
silverware and costume jewellery.

8. Under what circumstances brazing will be preferred over welding?

Brazing or soldering might be preferred over welding if (1) the base metals have poor
weldability, (2) the components cannot tolerate the higher heat and temperatures of welding, (3)
production rates need to be faster and less expensive than welding, (4) joint areas are inaccessible
for welding but brazing or soldering is possible, and (5) the high strength of a welded joint is not a
requirement.

9. Give and discuss the different tools needed for brazing?

 Filler

A filler metal and a source of heat to melt the filler. A brazing filler begins with one of
several common primary metals: silver, aluminum, gold, copper, cobalt or nickel. These primary
metals are then mixed, or alloyed, with other metals to improve or tweak their properties. For
example, manganese acts as melting point suppressant, meaning it lowers the temperature at
which the primary metal will melt. Chromium increases the strength of a brazed joint. And
boron can help increase resistance to corrosion.

 Rectorseal Flux
 Flux is used to avoid oxides from forming when the metal is being heated. A flux is used
in situations where the brazing operation is not carried out in an inert environment. Further
cleaning of any contamination remaining on the brazing surfaces is also achieved with the flux.
Flux can be in liquid, paste or powder form when it is applied. A flux core, or brazing rod with a
coating of flux can be used to apply the flux. When applied to the heated joint, the flux flows
into the joint, and is displaced by the liquefied or molten filler metal flowing at the joint.

 Brazing rods

Brazing has a low melting point making it easily machinable and excellent for sheet
metal work. This alloy possesses high tensile strength and good ductility.

 Brazing torch

Torch brazing, as the name implies, employs a hot gas torch on or near a joint to heat
the workpieces and melt the filler alloy being used to fill the gap. Because the filler materials
chosen should melt significantly below the workpieces’ oxidizing temperature, the joint is
protected from oxidization.

10. Assuming that we are back to school and you are given a chance to design and work on a project on
brazing, what project would you do and why?
I will make a dog cage for my project on brazing. We have dogs in our house so it is better if I
will provide a cage for them. In case we have a visitors, a dog cage will prevent our dogs from
biting our visitors. We can also

References

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joining/article/21831910/whats-the-difference-between-soldering-brazing-and-welding
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