Metal Joining

Tungsten Carbide
This article reviews
the development of
the filler metals and
fluxes used when
brazing tungsten
carbide.

Tungsten
Filler Metals and Fluxes for Brazing

Carbide
By Jack Willingham, Manager Quality & Technical Service Johnson Matthey Metal Joining

1
Tungsten Carbide

Contents

Brazing filler metals - 3

The background

Brazing filler metals - 5

The historical perspective

Brazing filler metals - 9

The technical considerations

Brazing fluxes - 17
The technical considerations

Brazing filler metals - 22

The common applications

2
Brazing filler metals -
The background
Many different types of brazing filler metal
are used to join sintered tungsten carbide to
a supporting backing material. Although many
different filler metal compositions are used
they can be divided into two principal groups.
Group 1
Copper and copper based filler metals
including the copper-zinc (brazing brasses)
and materials in the copper-zinc-nickel alloy
system, (widely known as nickel-silver, and
often used for bronze welding mild steel).
Group 2
Low melting point brazing filler metals
containing silver.
In addition to these two main groups there are
a number of other precious metal filler metals
that contain either gold or palladium that are
used in some specialised applications where
filler metals from the two main groups cannot
meet the demands of the application.
Of the two main groups, the silver containing
brazing filler metals are the ones most widely
used, particularly those that have a melting
point below 750˚C. Such filler metals are used
not only because of their technical suitability,
but also because they are easy to use due to
their conveniently low brazing temperature.
A further advantage of the low temperature
silver brazing filler metals is their compatibility
with the induction heating process, one of
the most commonly used heating methods in
applications involving the joining of tungsten
carbide to steel. This compatibility is as a
result of the low temperature silver brazing
filler metals having working temperatures
below the Curie point of iron. At the Curie
point (approximately 770˚C), iron changes
from being a magnetic- to becoming a non-
Tungsten Carbide
magnetic material. This change results in a loss
of heating efficiency, a reduction in the speed
of heating and a need to increase the energy
input to maintain the rise in temperature.
Functions of the brazing filler
metal
The primary function of any brazing filler metal
is to wet and bond with the parent materials
to be joined, and to form a joint that is robust
enough to withstand the loads that will be
imposed upon it in service. When brazing
tungsten carbide the brazing filler metal has
a further function to perform. It needs to
accommodate the stresses that develop in
the joint during cooling, as a result of the
significantly different coefficients of expansion
that almost always exist between the tungsten
carbide and the backing material to which it is
brazed.
Wetting and bonding
In most applications involving the brazing of
tungsten carbide, obtaining good wetting
and bonding of the filler metal to the backing
material is not normally a consideration. This
is because the most commonly used backing
material steel, is readily wetted by most
brazing filler metals that are used to braze
tungsten carbide. The ability of a brazing filler
metal to wet and bond to tungsten carbide is
somewhat more problematic and is a function
of the composition of the tungsten carbide,
namely:
1. Its cobalt content.
2. The nature and level of any other
metallic carbide added to its The primary function
composition other than tungsten of any brazing filler
carbide. metal is to wet
3. Whether it contains any free graphite and bond with the
/ carbon on its surface or within the parent materials to
matrix of the tungsten carbide itself. be joined.
3
Tungsten Carbide

Accommodating the inevitable to be subject to tensile-, shear- or compound-

post-braze stress bending stresses. In most applications
If the brazing filler metal is unable to involving the brazing of tungsten carbide,
accommodate the stresses that inevitably preventing it from cracking by accommodating
develop during the cooling of the joint, one or the cooling stress is the primary consideration.
more of four outcomes are possible:
Figure 2: Example of a joint that cracked
on cooling
1. The part distorts– See Figure 1.
2. The tungsten carbide cracks
– See Figure 2.
3. The joint fails completely and the
tungsten carbide tip comes off
– See Figure 3.
4. Nothing happens on initial cooling, but
the tungsten carbide cracks or comes
off in service or when the part is ground
– See Figure 4.

Outcomes 1, 2 and 3 present themselves as

obvious problems that immediately point to
Figure 3: Example of a joint where tip
the fact that there is something wrong with
has come off during cooling
the brazing process. Outcome 4, the ‘nothing
happens’ situation is the most concerning,
since unless the stresses that developed on
cooling of the joint have been accommodated
satisfactorily, the joints could contain a high
level of residual stress. Any load applied to
the joint during use or grinding increases
the level of stress in the joint resulting in
the tungsten carbide cracking or coming off.
Tungsten carbide can generally be considered
to be a brittle material, although this does
depend upon its composition. It does not like

Figure 1: Example of a joint that Figure 4: Example of a joint that cracked

distorted on cooling during grinding

4
Brazing filler metals -
The historical perspective
It would appear that tungsten carbide as
a material was first developed in the mid
1920’s. It seems that pure copper and 60/40
type brass brazing filler metals were the first
filler metal types to be used to join tungsten
carbide to a steel backing. In the mid to late
1930’s low temperature, cadmium- bearing,
quaternary silver brazing filler metals had
become available and also started to be
used. Between 1940 and 1944 the first
specialised silver brazing filler metal for the
brazing of tungsten carbide appeared. This
was the addition of 3% nickel being made
to a low temperature, cadmium-bearing,
quaternary silver brazing filler material. The
nickel addition enhances the filler metal’s
wetting and bonding capability onto tungsten
carbide. It also produces a thicker layer of
brazing filler metal within the joint, which
helps to accommodate the cooling stresses.
Nickel is now a common addition made to
the specialised tungsten carbide brazing filler
metals.
Manganese is another element commonly
present in many brazing filler metals used for
brazing tungsten carbide since it also improves
wetting and bonding. Again it would appear,
that while a filler metal with a composition
of 65% silver- 28% copper- 5% manganese
and 2% nickel existed in 1948, its use would
have been in applications involving elevated
temperature service, not for the brazing of
tungsten carbide. One reference from 1953
indicates the use of ‘high silver-content brazing
filler materials containing manganese’ as they
have ‘added readiness to wet certain types
of carbide’. Whether this is a reference to the
68% silver-content filler metal, or to the 15%
manganese – silver alloy is not clear. In the 1st
edition of the AWS Brazing Manual of 1955,
the 15% manganese-silver alloy is mentioned
for use in applications where subsequent heat
treatment of the backing material is required.
In the early- to mid- 1960’s a cadmium-bearing
quaternary based filler metal containing both
Tungsten Carbide
nickel and manganese came onto the market.
This filler metal was used initially for the brazing
of rock-drills before being adopted more
widely for the brazing of tungsten carbide.
Shortly after the appearance of the cadmium-
bearing filler metal with additions of nickel and
manganese, a ternary silver-copper-zinc alloy,
with additions of nickel and manganese, was
also being used to braze rock-drills. Both these
filler metals were subsequently adopted more
widely for the brazing of tungsten carbide, with
the 49% silver-copper-zinc-nickel-manganese
now being one of the most commonly used
filler metals for the brazing of tungsten carbide.
Running parallel with the development of
the silver-base filler metals were the copper-
base filler metals. The historical information
available concerning the development of
the copper-base filler metals is much less
abundant than for those with a silver-base.
Most of the filler metals seem to have been
developed to meet the requirements of
rock-drill brazing. The sketchy nature of
the information freely available is, perhaps,
not surprising, since the various companies
involved in the manufacture of rock-drills
between the 1960’s and 1980’s were very
secretive about their product development.
The main reason for the development of
the copper-base filler metals arose from the
need to replace the high silver content filler
metals in order to reduce material costs. (At
that time the 49 to 50% silver-content were
the favoured brazing filler metals). There
are also indications that in some cases the
silver containing filler metals were being
overheated in order to allow for simultaneous
heat treatment of the shank material. The
overheating above 750˚C would result in some
Nickel and
deterioration of the brazing filler metals due to
manganese enhance
the vaporisation of cadmium and zinc. In other
the filler metal’s
cases the inference is that the silver-base filler
wetting and bonding
metals were used because of their low brazing
onto tungsten
temperatures. This feature, together with rapid
carbide.
induction heating, allowed the brazing of fully
5
Tungsten Carbide
heat-treated shanks, as the short duration
of the brazing operation only had a minimal
effect on the already heat treated properties
of the shank material.
As already mentioned, pure copper was one
of the first brazing filler metals used to braze
tungsten carbide, although it has not been
possible to uncover any evidence that pure
copper was used to braze rock-drills. Some
evidence suggests that copper nickel filler
metals were used and certainly prior to 1967
a 96.9% copper-2.5% nickel-0.6% silicon
alloy, widely known as Corson Bronze, was
in extensive use. Since this material already
existed as a precipitation hardenable copper-
base filler metal it seems likely that brazing
tests carried out with it showed that it worked
acceptably. The high brazing temperature and
properties of this filler metal, while not ideal,
did allow for simultaneous brazing and air
hardening of the shank material, followed by a
lower temperature tempering heat treatment.
As indicated, the copper-nickel-silicon filler
metal is of a composition that can be subject
to precipitation hardening and there are
some suggestions that the high strength and
hardness of the filler metal prolonged the life
of drills used in certain drilling environments.
While the copper-nickel-silicon filler metal
was reasonably successful, it was not ideal.
It was found to be ‘hot short’ on cooling,
and go through a ductile, brittle transition at
around 600˚C. On larger diameter drills this
was known to cause internal cracking of the
filler metal due to the stresses that developed
during post-braze cooling of the joint, and this
resulted in premature service failure of the
drills due to fatigue.
Rock drills
The failings of the copper-nickel-silicon filler
metal prompted the development of copper-
manganese- cobalt filler metals. Their lower
brazing temperatures reduced the amount of
deterioration suffered by the shank material as
a result of the high brazing temperatures of
6
the copper- nickel-silicon filler material, while
also helping to minimise the cooling stress.
The manganese in the filler metal acted as a
melting point depressant while also providing
good filler metal wetting. Cobalt was added
to the filler metal composition, as opposed to
nickel, as it appeared that cobalt interalloyed
with the cobalt-bonded matrix of the tungsten
carbide more freely than nickel did. In the
finished braze joint, the cobalt is present as
a fine cobalt rich phase dispersed throughout
the filler metal, and this is said to produce
joints with a high resistance to fatigue failure
together with a good level of ductility.
While the copper-manganese-cobalt filler
metal overcame many of the shortcomings of
the copper- nickel-silicon filler metal, ideally
the rock-drill manufacturers were seeking
inexpensive brazing filler materials with brazing
temperatures as close to 850˚C as possible.
Brazing temperatures around 850˚C more
closely match the heat treatment temperature
of the steel shank and minimise the cooling
stresses. This requirement eventually resulted
in the early 1970’s in the development of a
brass type brazing filler metal with additions
of manganese and cobalt. The filler metal
produced joints, which greatly extended the
life of drills compared to those that had been
brazed with the previously used types of
copper-base filler metal.
A further important development in the field of
brazing tungsten carbide was the ‘sandwich’ or
tri-metal product. These filler materials have a
central core of material metallurgically bonded
on either side with a layer of brazing filler
material. In the early 1950’s it was common
practice when brazing large sections of carbide
to form these types of product in situ. Either
a plain sheet of material, woven soft iron wire
gauze or a corrugated metal foil was used to
thicken the brazed joint. The joint was prepared
by first laying a section of fluxed brazing filler
metal in foil form onto the joint area, then the

interlayer material, and finally by another piece
of fluxed brazing filler metal foil on top. The
reason for thickening the joint by introducing a
spacing layer was to allow the joint to deform
more readily such that it could dissipate the
greater levels of cooling stresses that occur
when brazing large sections of carbide.
It has not been possible to establish precisely
when purpose made tri-metal products, where
the brazing filler metal had been pre-bonded
to the interlayer, first became commercially
available. However, the 1st Edition of the
AWS Brazing Manual from 1955 states that “A
special brazing sheet is available for making
sandwich brazes. This consists of a copper
core clad on both sides with a thin layer of
nickel-bearing BAg filler metal.” By the mid
1960’s such products were in common use.
Typically, the product consisted of a copper
or copper, nickel interlayer, with a silver-base
brazing filler metal bonded on either side.
Some of the high temperature copper-base
filler metals were also available as tri-metal
products, with gauze woven from nickel wire
being used as the interlayer material.
Tungsten Carbide
been available up until the later 1970’s,
early 1980’s, but they have now started to
re-appear with cores described as ‘copper
alloy’. The products would seem to offer joints
with higher shear strengths, as the copper
alloy core will be stronger than products
using the more common ‘pure copper’ core.
This additional strength is seen as being
advantageous in applications where carbide
tips are subject to high impact service loads.
It is also possible to obtain what are commonly
referred to as ‘tri-metal’ brazing pastes. This
description is used to describe brazing pastes
that produce joints with a thick layer of filler
metal, similar to the tri-metal products by
introducing into the paste formulation a metallic
powder that is not easily dissolved and taken
into solution when the brazing filler is molten.
Typically nickel powder is used for this.
Circular saw blade

Today copper in the form of a solid sheet of

material is most commonly used as the core or
interlayer material in most tri-metal products.
Copper is used not only because it is soft and
ductile and can deform easily to dissipate the
cooling stresses, but also because it makes
for easy bonding of the brazing filler metal
layers during production of the products. The
common ratio of the layers in the products is
1:2:1. For example, in a 0.4 mm thick product
the first layer of brazing filler metal will be 0.1
mm thick, followed by the interlayer with a
thickness of 0.2 mm and then another layer
of filler metal 0.1 mm thick. Other ratios
with a thicker interlayer or thicker brazing
filler metal layers are also available. Recently
there has been a re-emergence of tri-metal
products with copper alloy cores. Products
with a copper-nickel core had traditionally

7
Tungsten Carbide
The most recently developed filler metals are
silver containing, and are free from both zinc
and cadmium. These have been developed
for use when the tungsten carbide and its
backing are to be coated using a Physical
Vapour Deposition (PVD) process to apply
TiN (titanium nitride) and similar types of
coatings (See Figure 5). Under the coating
conditions, if present, the cadmium and zinc
will tend to vaporise out of the brazing filler
metal affecting the coating process. They
act as melting point depressants within the
filler metals and while it is possible to have
silver-copper-nickel-manganese filler metals
without these volatile elements, their brazing
temperatures are quite high. Filler metals
with lower brazing temperatures, but still
containing the beneficial elements nickel and/
or manganese, have been produced where
indium or tin have been added as melting
Figure 5: Titanium nitride (TiN) coated gun drill
8
point depressants. (See Argo-braze® 64 and
Argo-braze® 57 in Table 4). While both tin and
indium are low melting point elements they
have high vaporisation temperatures.
The above comments cannot be considered all
inclusive, but they do at least chart the major
filler metal product developments made in
connection with the need to braze tungsten
carbide while attempting to attribute some
approximate dates and chronological order to
those developments.
It is interesting to note that most of the brazing
filler metals and products specially developed
for the brazing of tungsten carbide are still
being used today. However, the use of the
cadmium-bearing filler metals is in major decline
due to the health and safety issues that arise
from their use and environmental pressures.
Brazing filler metals -
The technical considerations
Filler metal wetting and bonding
It has already been highlighted, that
obtaining good wetting and bonding of a
brazing filler metal onto tungsten carbide
is not as straightforward a proposition as it
can be for many other materials. Where the
cobalt content of the tungsten carbide is
above approximately 6%, both the common
quaternary silver-copper-zinc-cadmium and
the ternary silver-copper-zinc filler metals
will wet and bond with tungsten carbide
relatively easily. However, wetting becomes
more difficult when other metallic carbides are
added to the carbide, particularly the refractory
metal carbides of titanium and tantalum. In
such cases levels of only 1 to 2% have very
serious effects on filler metal wetting. Free
graphite or carbon within the matrix of the
tungsten carbide can also impair filler metal
wetting.
It is apparent from the historical perspective,
that improved wetting and bonding of the filler
metals for use when brazing tungsten carbide
has been one of the main development
themes. We have seen that nickel was the
first element to be added to the silver brazing
Figure 6: Colour comparison AWS A5.8 B-Ag24 manganese free and EN 1044 AG502
manganese containing filler metals
Tungsten Carbide
alloys in an attempt to improve wetting and
bonding. Nickel is known to change the
nature of the bond that is created from
one of an intermetallic nature to that of an
interalloying type. Cobalt is also known to
have a similar effect. Manganese is another
element that has been found to improve the
wetting and bonding of filler metals. Filler
metals containing manganese are particularly
useful when brazing carbides that contain
additions of titanium and tantalum carbides,
as they have a much greater ability to wet
such carbides than filler metals that contain
only nickel. Manganese also seems to have
the ability to wet surfaces containing graphite,
so again filler metals that contain manganese
show improved wetting on those tungsten
carbides that contain free graphite / carbon on
their surfaces or within their matrix. Nickel and
manganese also improve filler metal wetting
Nickel and
and bonding on tungsten carbides having low
manganese also
cobalt contents.
improve filler
metal wetting and
It has not been possible to find information
bonding on tungsten
that suggests that any real scientific or
carbides having low
metallurgical thought processes (at least
cobalt contents.
in the early development of the specialised
9
Tungsten Carbide
brazing filler metals for use on tungsten
carbide) existed in relation to the additions
of nickel and subsequently manganese. It
would seem that their beneficial effects were
established on an empirical basis early on and
this information was then used to formulate
subsequent filler metal compositions.
When selecting a brazing filler metal for
a tungsten carbide brazing operation it is
established practice to use filler metals that at
least have an addition of nickel or better still
additions of nickel and manganese. However,
Most specialist
some resistance does exist to the use of
tungsten carbide
the manganese bearing filler metals. This is
brazing filler metals
sometimes as a result of the surface finish
contain at least
of the filler metal that can have a rough and
an addition of
dark reddish brown appearance (See Figure
nickel, and many
6). Some operators dislike these filler metals,
contain additions
as they are more ‘sticky’ than those that are
of both nickel and
manganese-free. In many tungsten carbide
manganese or cobalt
brazing operations an operator is required to
and manganese.
move the tungsten carbide tip around when
Figure 7: Example of a wetting test
10
the brazing filler metal is in its molten state to
help remove any flux and gas trapped in the
joint before finally positioning the tip in its
correct location. The term ‘sticky’ is a reference
to the fact that the tungsten carbide tips do
not float and move so easily on the molten
brazing filler metal, so making it difficult for
the operator to move and position them.
Some do not like the nickel bearing filler
metals either, since they do not flow as well
as the straight quaternary silver-copper-zinc-
cadmium or the cadmium-free silver-copper-
zinc-tin filler metals.
It is easy to check how a particular filler metal
and flux combination will wet onto a piece of
tungsten carbide. Simply clean the face of the
tungsten carbide piece that would be brazed
in the normal way. Flux the surface, and then
cut a section of brazing filler metal foil, rod or
wire and place it on top of the fluxed surface
of the tungsten carbide. Finally apply more
flux over the top of the cut section of filler
Position 1. EN1044
AG305 & standard flux
EN1045 Type FH10
Position 2. EN1044
AG103 & boron modified
flux EN1045 Type FH12
Position 3. A5.8 B-Ag24
& standard flux EN1045
Type FH10
Position 4. EN 1044
AG103 & standard flux
EN1045 Type FH10

metal. It is then simply a question of heating
the tungsten carbide until the filler metal
melts. Once the piece of tungsten carbide has
cooled down remove the flux residues. A visual
assessment shows how well the filler metal
has wetted and spread. By using different
filler metal and flux combinations it would be
possible to determine which combination gives
the best results for the carbide in question.
(See Figure 7)
This very basic test can throw up issues when
the pieces of tungsten carbide start coming off
rather than finding there is a problem when a
whole batch of parts has been brazed and is
in use. By using a controlled size and shape of
filler metal this standard wetting test can be
used as a pre-production check on batches of
tungsten carbide. It can also be used to check
the effectiveness of the pre-braze cleaning of
the tungsten carbide.
Figure 8: Diagram depicting mismatch in expansion between a tungsten carbide tip
and its support backing at brazing temperature
Backing of Material
Tungsten Carbide
Accommodating the cooling
stresses
As previously mentioned, due to the significant
mismatch in expansion coefficients that
typically exist between the tungsten carbide
and the backing material to which it is brazed,
whichever brazing filler metal is used it needs
to be able to accommodate the stresses that
develop within the joints on cooling,
When cooling a joint, the backing material
wants to contract faster and further than the
piece of tungsten carbide to which it is now
securely brazed. (See Figure 8) This mismatch
results in the development of shear stresses
within the joint. If the brazing filler metal has
a high strength it will transmit these stresses
directly into the relatively brittle tungsten
carbide and cause it to crack. What is required
is brazing filler metal that has a low yield point
that will deform plastically allowing the stress
to be dissipated. Unfortunately, the strength
Expansion of Tungsten Carbide
Tungsten Carbide
Expansion of Backing
11
Tungsten Carbide

Figure 9: Results of tensile tests showing how joint clearance and the strength of
the parent materials affects joint strength.

a b
84
U.T.S of Drill Rod U.T.S of Drill Rod
E
70
F
E
Tensile Strength Kgf/mm2

F G
56 G H
U.T.S of 1020 Steel A U.T.S of 1020 Steel
A
B
42 H
C B
I C
D D
28

U.T.S of Pure Silver U.T.S of Pure Copper

14

0
0 0.127 0.254 0.267 0.508 0.635 0 0.127 0.254 0.267 0.508 0.635

Joint Thickness mm Joint Thickness mm

The effect of joint gap (joint thickness) on the tensile strength of brazed butt joints (after
Bredzs). The strength of silver (a) and copper (b) brazed joints in steel 1020 is represented
by curves ABCD, curves EFGH relating to joints brazed in drill rod steel. The U.T.S. of silver,
copper and parent metals is indicated in the graphs

of brazing filler metal in a brazed joint is not
primarily a function of the strength of that
filler metal, but the strength of the parent
materials and the thickness of the brazing filler
metal layer within the joint.
Practical testing has shown that if, for
example, an ordinary carbon steel and high
strength carbon steel are brazed with the
same brazing filler metal, the ordinary carbon
steel joint will be weaker than that made in
the high strength steel (See Figure 9). It is also
understood that the thickness of brazing filler
metal in a joint has a strong influence on the
strength of a brazed joint - the thinner the
joint the higher its strength. It is possible to
develop joint strengths that are 2 to 3 times
greater than that of the ‘as cast’ strength of
the brazing filler material.
The situation that is found in a typical brazed
joint is that there is a thin layer of a relatively
weak, ductile, filler metal bonded securely
to two much stronger, less ductile parent
materials. When such a joint is subjected to
a tensile load, if the load applied to the joint
is above the yield point of the brazing filler
metal, then the filler metal would be expected
to begin to deform in the same manner as
a tensile test specimen by ‘necking in’. (See
Figure 10) However, the thin layer of filler metal
is securely bonded to the two parent materials,
which prevents it from doing so. Brazed
joints therefore typically fail under tri-axial
stress conditions and show very little ductile
deformation, failing in an almost brittle mode.

12

Figure 10: Results from Tensile Loading
Necking under
tensile load
Taking the above into account, the normal
perception that a strong joint is required when
brazing tungsten carbide could be questioned.
It can be understood that if too strong a joint
is produced it will not be able to deform to
dissipate the cooling stresses. If the filler
metal is too strong it will simply transmit the
stress into the component causing it to distort
or the piece of tungsten carbide to crack to
relieve the stresses that have developed. If the
levels of stress developed during cooling are
extremely high, and the component sufficiently
robust such that it cannot distort or crack, the
brazing filler metal itself can rupture resulting
in the piece of tungsten carbide becoming
detached. It is also possible in circumstances
where the component is sufficiently robust
for the stresses developed on cooling to be
contained as residual stresses within the
component. The residual stresses locked up
in the joint only show themselves when some
additional stress is added to the component
by the application of some external force,
Tungsten Carbide
Necking constrained by
bond to parent material
either a physical mechanical load or thermally
generated stresses.
It follows from the preceding text, that when ‘…when brazing
brazing tungsten carbide, joints with a good tungsten carbide,
level of ductility are required, such that they joints with a good
can deform readily and allow the stresses level of ductility are
that arise on cooling to be dissipated. It also required, such that
follows, that strong joints, where only a thin they can deform
layer of brazing filler metal is present between readily and allow the
the tungsten carbide and its backing material, stresses that arise
will not allow the brazing filler metal to deform on cooling to be
in a ductile fashion, and therefore will not dissipated.’
allow dissipation of the cooling stresses.
Joints that have a thick layer of brazing filler
metal between the tungsten carbide and the
backing material will be more able to deform
and therefore allow dissipation of the cooling
stresses. In essence ductile joints are required,
which usually means thick joints, which in turn
means joints are going to be lower in strength
than might be the case for other joints.
13
Tungsten Carbide
From the need to produce ductile joints three
1.
approaches in relation to the selection of
brazing filler metal for applications involving
the brazing of tungsten carbide have evolved:
2.
These three approaches are particularly applied
in the case of selecting silver-base filler
3.
metals, where some general rules have been
developed, based on the size of carbide that
can be brazed successfully.
The general rules
1. For pieces of tungsten carbide where
the maximum dimension does not
exceed 10 mm the use of conventional,
ductile silver brazing filler metals like
EN 1044 AG102, 103 (56 & 55% silver
cadmium-free with tin) and 301, 302
and 303 (50, 45 & 42% silver with
cadmium) can be used
(See Tables 1 & 2).
These free flowing filler metals that are
relatively ductile tend to produce joints
containing a relatively thin layer of brazing
filler metal, which limits the size of carbides
2. For pieces of carbide where the
maximum dimension is between 10 and
20 mm, the use of the nickel or nickel
and manganese bearing filler metals
is recommended. EN1044 filler metals
AG502, 351 and AWS A5.8 BAg-24 (See
Table 3)
The addition of nickel to these filler
metals reduces their flow properties and
helps them to produce joints that have a
naturally thicker layer of brazing filler metal
than the standard filler metals. Because
of the reduced flow properties of these
filler metals they are best pre-placed in
the joint as a section of foil as opposed to
being hand fed into the joint from wire or
14
The use of filler metals that possess a
high level of ductility.
The use of filler metals that produce
joints with thicker than normal layers of
filler metal.
The use of products or methods that
produce artificially thick brazed joints.
that can be brazed successfully. A further
advantage of these filler metals is their
low brazing temperatures, which help
to minimise the amount of differential
expansion developed between the
tungsten carbide and the backing material.
The high silver content cadmium-bearing
filler metals tend to have higher levels
of ductility than the cadmium-free filler
metals, and therefore may be capable of
brazing a wider range of sizes and shapes
of tungsten carbide than cadmium-free
filler metals.
rod. Pre-placing the filler metal in the joint
allows it to produce the thickest possible
joints, so allowing the filler metals to be
used to their full potential.
The additions of nickel and manganese
to the filler metals increase their ‘as cast’
strengths, which to some extent are offset
by the thicker joints they produce. In a few
cases problems have been encountered
when changing from the cadmium-bearing
filler metals with additions of nickel and
manganese to the cadmium-free filler
metals containing nickel and manganese.
While there had been no problems using
the cadmium-bearing filler metals, with
the change to cadmium-free materials

2. cracking problems started to occur. These
problems tended to be in applications that
were at the extreme of the capabilities of
the cadmium-bearing filler metals. It was
clear that the filler metal, EN 1044 AG502
(49% silver with nickel and manganese)
was stronger and less ductile than the
cadmium-bearing filler metals previously
used.
While the AG502 filler metal with its high
levels of nickel and manganese is the
filler metal most widely used for brazing
tungsten carbide in Europe and other
3. Where the largest dimension of the
tungsten carbide is greater than 20 mm
then the use of the tri-metal products
is recommended.
The interlayer in the tri-metal products
produces a thick, ductile joint capable of
dissipating significant amounts of stress.
The tri-metal products come in various
thicknesses; the thickness used in any
application being a function of the size
of the piece of tungsten carbide. i.e the
larger the piece of tungsten carbide, the
greater the thickness of tri-metal. In the
past, the tri-metal products were coated
with the cadmium containing filler metals,
EN 1044 AG301 or the nickel containing
AG351. By far the most commonly used
product today is the cadmium-free 49%
silver-copper-zinc alloy containing additions
of nickel and manganese. The filler metal
used is a modified version of the EN 1044
AG502, where the nickel and manganese
The above can only be seen as general
guidelines to the selection of a filler metal,
as they are based only on the size of the
piece of tungsten carbide. Another factor that
also needs to be considered is the ductility
of the tungsten carbide. This is a function of
the cobalt content of the tungsten carbide,
Tungsten Carbide
parts of the world, the AWS A5.8 BAg-24
filler metal (50% silver-copper-zinc-nickel)
is equally common in the United States.
As previously mentioned the nickel and
manganese bearing AG502 filler metal is
disliked by some due to the colour of the
finished braze - a dark red brown, and
it is ‘sticky’ making it difficult to move
and position pieces of tungsten carbide.
The BAg-24 filler metal does not contain
manganese and therefore does not exhibit
these characteristics, and as a result some
users in Europe are now favouring it.
contents have been significantly reduced.
The reason why this modified filler metal
is used, as opposed to high nickel and
manganese AG502 filler metal is to
facilitate manufacture of the product. When
the need arose for cadmium-free tri-metal
products, attempts were first made to use
the standard AG502 filler metal. However,
problems with de-lamination of the layers
and edge cracking during rolling (due to
the different work hardening characteristics
of the copper interlayer and the filler
metal) resulted in the development of the
modified filler metal.
As previously mentioned, the manganese
containing filler metals are disliked by some
due to the colour of the finished braze
and their stickiness. Tri-metals using the
manganese free AWS A5.8 BAg-24 are
available and are now preferred in some
cases.
the higher it is the more ductile it will be.
The thickness of the tungsten carbide is
also important as the thicker it is the more
robust it will be. The shape of the tip is also
important, since if it has a complex shape with
changes in width, thickness and includes sharp
corners, as for example in certain router bits,
15
Tungsten Carbide
then these changes in form can be points of
stress concentration, increasing the likelihood
of the tungsten carbide cracking. These
additional factors may mean that although it is
possible to braze the piece of tungsten carbide
based simply on its size with say a standard
ductile filler metal, due to its shape it would
be prudent to use a nickel bearing filler metal
that produces a thicker joint with more stress
dissipating capacity.
A tri-metal product could be used, although
the size of the piece of tungsten carbide does
not really warrant its use, in applications where
the tungsten carbide in use experiences impact
or percussive loads. In these applications
the tri-metal can act to cushion the loads
applied to the tungsten carbide and stop it
from cracking. In some applications, while it
prevents cracking of the tungsten carbide,
deformation of the interlayer under the service
loads can result in cracking problems or joint
failures. In such circumstances the use of a
tri-metal product with a copper alloy interlayer,
16
as opposed to a pure copper one, is likely to
prove beneficial.
In addition to using specific brazing filler
metals or products as an aid to dissipating
the cooling stresses, slow controlled cooling
of joints following brazing is important. Also
of importance are those methods that seek
to produce thick layers of brazing filler metal
between the tungsten carbide and its backing
material. As already mentioned, joints were
historically thickened by using a layer of woven
wire mesh or foil and while tri-metal products
are commercially available, the ‘do it yourself
approach’ could be considered if a suitable
commercial product is not available. Simple
spacer wires can also be used to provide a
controlled and thick joint clearance. Raised
bars or pips formed on either the tungsten
carbide or the backing can be another way
in which to produce a suitably large, yet
controlled, joint clearance.
Brazing fluxes -
The technical considerations
The vast majority of joints made between
tungsten carbide and a backing material are
made in air using flame- or induction heating.
This means that the filler metal needs to be
used in conjunction with a suitable flux.
1. The flux must be able to remove the
oxides found and formed on the parent
materials and the filler metal during the
brazing operation.
2. Its active range should be compatible
with the brazing temperature of the filler
metal.
3. The flux should become active at least
50˚C below the filler metal’s solidus
temperature.
4. The flux should have a molten viscosity
such that it can be easily displaced from
the joint by the molten filler metal at the
brazing temperature.
5. It should have sufficient time / stability
to survive the brazing operation.
Figure 11: Lathe tool coated with a boron modified EN1045 Type FH12 flux
ready for brazing
Tungsten Carbide
Removing the oxides from the
parent materials and filler metal
It is perhaps obvious that a flux should remove
the oxides found and formed on the parent
materials. However, not all fluxes are capable
of removing all oxides. For example, traditional
borax, boric acid type fluxes are not good
at removing nickel, zinc or refractory metal
oxides.
Most modern fluoroborate containing fluxes
are very good at removing most oxide types
and are used in most tungsten carbide brazing
applications quite successfully. However, the
standard fluxes still find it difficult to deal with
refractory metal oxides, and where titanium
and tantalum carbides are present within the
formulation of the tungsten carbide then the
use of the special boron-modified fluxes is
recommended. These fluxes are recognisable
by their brown or dark brown to almost black
colour. The boron-modified fluxes contain
as part of their formulation elemental boron
powder. The addition of the elemental
boron not only changes their colour, but also
makes them highly active against refractory
17
Tungsten Carbide
oxides. There is also some practical evidence
that boron containing brazing fluxes aid the
wetting of filler metals where the parent
materials contain some free graphite, which as
previously explained can be present in some
tungsten carbides. Tungsten carbides with low
cobalt contents also exhibit improved wetting
when brazed using boron-modified fluxes.
One criticism of the boron-modified fluxes is
that their dark colour prevents operators from
seeing what is happening during the brazing
operation, masking the flow of the filler metal.
Many of those engaged in the brazing of
tungsten carbide will use nothing other than
the boron-modified fluxes. The combination
of a nickel and manganese bearing filler metal
together with a boron-modified flux will give
the best wetting and bonding performance
whether the carbide is straightforward
tungsten carbide, a carbide with a low cobalt
content, one that contains additions of
titanium and tantalum carbide or one where
free graphite is present.
Compatible active range
It is important when selecting a flux that the
active range of the flux is compatible with the
It is commonly brazing temperature of the filler metal. The flux
understood that needs to be active and removing the oxides
fluxes remove the on the parent materials, and any filler metal
oxides from the pre-placed in the joint, before the filler metal
parent material begins to melt. Likewise, using a flux where
and then prevent the filler metal melts beyond the stated active
further oxidation range of the flux is likely to prove problematic,
from taking place. because it will tend to end up in a burnt
However, this is not and blackened condition and incapable of
strictly the case. removing any oxides. Typical examples of such
a mismatch are the use of the borax, boric acid
based fluxes designed for use with the brass
brazing filler metals, with the low temperature
silver brazing filler metals. The borax boric acid
based fluxes are not active much below 750˚C,
which is of course well above the melting
point of silver brazing alloys. The reverse of
this situation also applies, that is the use of
the fluoroborate based fluxes formulated for
18
use with the silver brazing filler metals being
used with the brass brazing filler metals. The
upper active range of the silver brazing filler
metals’ fluxes tends to be in the order of
800˚C, but the brass brazing filler metals have
brazing temperatures around 900˚C.
The active temperature range of a
flux for best practice results
As already mentioned, in a brazing operation
a flux needs to be active and removing the
oxides from the parent materials and any
filler metal pre-placed in the joint before the
filler metal melts, and maintain its activity
until the filler metal has flowed and made the
joint. In practice, it has been found that the
flux needs to become active and efficiently
removing oxides at a temperature at least 50˚C
below the filler metal’s solidus temperature,
(the temperature at which it starts to melt),
and remain active at a temperature which is
at least 50˚C above the liquidus temperature,
(the temperature where the filler material
becomes completely liquid). The physical
melting of a flux does not necessarily indicate
that it has become active, or at least active
enough to start removing oxides efficiently.
The requirement for the flux to become active
at a temperature 50˚C below the solidus of
the filler metal is to allow the flux enough
time to remove those oxides that have formed
during the heating of the joint from room
temperature to the brazing temperature.
The joint will be subject to oxidation from the
onset of heating until the flux becomes active.
This will mean that for typical fluxes used with
a silver brazing filler material the joint will have
already attained a temperature of about 550˚C
before the flux becomes active. Clearly, the
oxidation that has occurred has to be removed
before brazing can occur. Consequently, when
the flux becomes active it will begin to remove
the oxidation that has built up during the pre-
heating stage. Naturally, time is needed to do
this, and if insufficient is provided the oxide

layer that remains on the work when the filler
material melts will impede the wetting and
flow of the molten filler material.
Viscosity of a molten flux
It is important that when the brazing filler
metal attains brazing temperature the viscosity
of the molten flux is such that that it can
be easily displaced from the joint by the
advancing front of the molten filler material. If
the viscosity of the flux is too high at brazing
temperature, and the filler metal is unable to
displace it the flux will almost certainly become
trapped in the joint. This type of problem can
result in joints that contain a high level of flux
inclusions. Flux manufacturers formulate their
fluxes with this problem in mind. However,
there may be technical circumstances where
due to the size and mass of the parts a
flux with good time-temperature stability
is being used with a low melting point filler
metal. While the flux may have good time-
temperature stability, its molten viscosity
at the lower end of its active range may be
such that it cannot be easily displaced by the
molten filler metal. Molten viscosity curves
for fluxes are not linear; thus it might be that
at 650˚C the flux is quite viscous, whereas at
700 it is very fluid. Every flux is different, so in
cases where joints exhibit a high level of flux
inclusions this is one factor to be considered
when trying to reduce the occurrence of the
problem.
The viscosity of a flux will also change during
a brazing operation due to the absorption of
oxides. Changes in viscosity tend to become
an issue where a flux is being used at the
upper end of its active range or where it has
been subjected to prolonged heating. This
situation may suggest that a flux with a higher
active range or with greater time-temperature
stability should be used.
Tungsten Carbide
Time-temperature stability
It is commonly understood that fluxes remove
the oxides from the parent material and then
prevent further oxidation from taking place.
However, this is not strictly the case. While
fluxes do remove oxides from the parent
materials they do not prevent further oxidation
of the parent materials taking place. In fact
there is a continual process during a brazing
operation of oxygen diffusing through the
layer of molten flux, oxidising the parent
materials beneath and the flux removing the
oxide that has been formed. Molten fluxes do
tend to act as a partial barrier to the diffusion
of oxygen, but this is a variable characteristic
dependent upon the flux formulation and its
temperature.
This continual process of oxygen diffusing
through the molten flux and the flux removing
the oxide that has been formed eventually
results in the flux becoming spent / exhausted,
as it becomes saturated with oxides and so
unable to remove any more. Clearly, if the flux
has become spent or is losing its ability to
remove oxides efficiently before the filler metal
is molten, the filler metal will not wet the
parent materials successfully.
The time-temperature stability of a flux is not
something that can be defined numerically, but
is rather a concept to explain a characteristic This continual
of a flux. For example, if a standard flux with process of oxygen
an active range of 550 to 800oC is used with diffusing through
a silver brazing filler metal with a brazing the molten flux and
temperature of 750oC, then immediately the the flux removing
joint starts to be heated the parent materials the oxide that
will begin to oxidise. When the flux becomes has been formed
active at 550˚C it starts to remove the oxides eventually results
that have formed up to that point, and more in the flux becoming
are still continuing to form. The phase is then spent / exhausted,
reached where oxygen diffuses through the as it becomes
molten flux, oxidation of the parent material saturated with
continues, and the flux continues to remove oxides and so unable
the oxides as they form. to remove any more.
19
Tungsten Carbide
It can be understood that more oxide will be
formed if it takes 5 minutes to get to the
brazing temperature of 750˚C as opposed
to 2 minutes. If after 4 minutes, the flux has
become loaded with oxide and has become
exhausted, then when the brazing filler metal
melts the surface will not be oxide-free and
will not wet successfully. In such an example,
the use of a filler metal with a brazing
temperature of 650˚C would be possible,
assuming that the joint could be heated to
650˚C in less than 4 minutes.
The speed at which a flux will become
exhausted is a function of how much oxide
is formed during a brazing operation. If the
thermal masses of the parts to be heated are
Unlike brazing
significant and it takes an extended period to
filler metals there
achieve the brazing temperature then the flux
are no standard
will be required to remove oxides from the
flux compositions.
parent materials over an extended period. It
Fluxes are all made
can be appreciated that heating a joint may
to proprietary
not involve a linear temperature rise. For
formulations and
example, while it might be possible to heat a
will therefore all
component to a temperature of 500˚C in two
have different
minutes, it may take a further 4 minutes to
properties and
achieve a temperature of 750˚C. Furthermore,
characteristics.
since oxide formation is a chemical reaction,
the higher the temperature the faster it goes.
In simple terms this means that a flux when
used at the lower end of its active range will
have a longer life than at the higher end of
its temperature range. In practical terms this
means that while a flux with an upper active
range of 800˚C could be used to make a joint
with a filler metal melting at 800˚C, there
would only be seconds available to make the
joint. This might be possible for small parts
using HF induction heating. In general, a flux
with an upper active range of 800˚C should
not be considered for use with filler metals
melting above 750˚C. Applying this restriction
means that the flux will still have some useful
life available when the filler material melts and
flows.
20
Flux selection
Unlike brazing filler metals there are no
standard flux compositions. Fluxes are all
made to proprietary formulations and will
therefore all have different properties and
characteristics. EN 1045 Brazing “Fluxes for
brazing – Classification and technical delivery
conditions” is, as it indicates, a means by
which manufacturers can apply some standard
classification to their flux products, but the
standard does not go beyond specifying
some basic flux characteristics and uses. In
manufacturers’ literature, where reference
is made to EN1045, many fluxes are given
the same classification, yet they clearly have
different properties and characteristics.
Unlike a brazing filler metal, where it is an
easy matter to conduct a chemical analysis
to determine its make up, it is not possible
to do this with fluxes. A chemical analysis
will not be able to determine the specific
chemical compounds that have been used to
formulate the flux, as many of the compounds
react during manufacture, and it is how they
are proportioned and reacted together that
determines the components, properties
and characteristics of the finished flux. In
selecting a flux for any particular application
the above points need to be considered.
Most manufacturers provide information in
their literature about the active range of the
flux and give some indication about its life
or overheat resistance. There may also be
additional information related to some special
characteristics of the flux, for example its
suitability of use when using HF induction
heating. This basic information should
allow anyone to select a flux suitable for an
application. However, a discussion with the
flux manufacturer is likely to be beneficial as
they will be aware of the subtle differences
in their products and may, based on the
details of the application, be able to suggest
a flux that offers specific advantages in that
application. Rather than just selecting one flux
 Tungsten Carbide
from a manufacturer’s range, it could well be
worth testing two or three that appear to be
suitable, to see which provides the best ‘on-
the-job’ performance.

The fact that fluxes are proprietary

formulations often causes problems if one
wants to change from one manufacturer’s
product to another’s. Operators will say that
the flux does not work as well. This could be
the case, but in many cases what the operator
is really saying is that it works differently or
perhaps more likely that it reacts differently
when heated. This is to be expected, as each
formulation will result in a flux with different
characteristics. What must be assessed is
whether the differences are good, bad or
indifferent, and whether the joints produced
are of an acceptable quality.

21
 Brazing filler metals -
Tungsten Carbide

The common applications

The cadmium-bearing filler metals were for
many years the principle filler metals employed
for the brazing of tungsten carbide in a wide
range of applications from lathe tools to rock-
drills.
The use of cadmium-bearing filler metals
is in decline due to the health and safety
implications associated with their use and
environmental and product stewardship issues.
Indeed in many countries of the EU, cadmium-
bearing filler metals are no longer being used.
EU Directives and legislation have already
effectively banned the use of cadmium-bearing
filler metals in any automotive application and
in the manufacture of any electrical or electronic
Most of the brazing
equipment, since a maximum cadmium level
filler metals and
of 0.01% has been imposed on any materials
products specially
used in the manufacture of such items. It has to
developed for the
be considered how long it will be before other
brazing of tungsten
EU Directives or legislation prevent their use in
carbide are still
other applications or completely bans the sale
being used today.
of cadmium-bearing filler metals. In addition
However, the use of
to the Directives and legislation, the growing
the cadmium-bearing
interest by major companies in the subject of
filler metals is in
‘Product Stewardship’ is leading to individual
major decline due
companies applying their own restrictions based
to the health and
upon the Directives and legislation already in
safety issues that
place. As a supplier or manufacturer it may, for
arise from their use
example, not be possible to supply a company
and environmental
with a cutting tool that has been brazed with a
pressures.
cadmium-bearing filler metal.
In view of the above it would seem prudent
to select a cadmium-free brazing filler metal
for use in any tungsten carbide application,
and to phase out the use of cadmium-bearing
filler metals as soon as possible before EU
Directives, legislation or individual companies
prevent their use.
The two main filler metals used from this group
are Easy-flo® and Easy-flo® No. 3 in Table 1.
Easy-flo® is a filler metal that possesses a level
of ductility that is around 35% in the ‘as-cast’
condition. Mattibraze™ 45, Easy-flo® No. 2 and
DIN Argo-flo™, possess a lower ductility, the
range extending from 20-25% for Mattibraze™
45 and Easy-flo® No. 2 with DIN Argo-flo™
being only 15%. As a result, Easy-flo®,
Mattibraze™ 45 and Easy-flo® No. 2 represent
the first choice filler metals for brazing most of
the easily wetted types of tungsten carbide,
and where the largest dimension of the carbide
is less than 10mm.
These five filler metals are extremely free
flowing and therefore demonstrate good
capillary flow, which together with their low
brazing temperature make them ‘user friendly’
and easy to use. Typically these filler metals
are hand fed into the joint as rod or filler wire,
but can be pre-placed as sections of foil. When
applied as a foil the production of a thicker
joint, which will provide better dissipation of

Table 1: Nominal compositions of the common silver-base, cadmium-

bearing filler metals used for the brazing of tungsten carbide
Silver Copper Zinc Cadmium Nickel Manganese Melting
Filler Metal EN 1044
% % % % % % Range ˚C

Easy-flo® 50 15 16 19 - - 620-630 AG301

Mattibraze™ 45 45 15 16 24 - - 605-620 AG302

Easy-flo® No.2 42 17 16 25 - - 610-620 AG303

DIN Argo-flo™ 40 19 21 20 - - 595-630 AG304

Easy-flo® No.3 50 15.5 15.5 16 3 - 635-655 AG351

Argo-braze ® 50 50 13.5 15.5 16 3 2 639-668 Prop

22

the cooling stresses, is much more likely to
result than when hand feeding rod or wire.
Mattibraze™ 45, Easy-flo® No. 2 and DIN
Argo-flo™ represent less expensive alternatives
to Easy-flo®, but due to their lower ductility
(particularly DIN Argo-flo™) there is some
restriction on the size of tungsten carbide that
can be brazed in comparison to those that
might be brazed with Easy-flo®.
For applications involving pieces of tungsten
carbide, with dimensions greater than 10mm,
but less than 20mm, Easy-flo® No. 3 and
Argo-braze® 50 are the natural choice. They
would also be chosen where one of the ‘more
difficult to wet’ grades of tungsten carbide
is to be brazed, this being particularly the
case with Argo-braze® 50 since it contains
manganese. The nickel and manganese
additions to these filler metals significantly
Table 2: Nominal compositions of the common cadmium-free filler
metals
Filler Metal Silver % Copper %
A* 56 19
Silver-flo® 56 56 22
Silver-flo® 55 55 21
* This filler metal currently not available from Johnson Matthey
The standard cadmium-free filler metals,
Silver-flo® 56 and Silver-flo® 55, are the ones
that have replaced the first four cadmium-
bearing filler metals in Table 1. However, their
ductility is generally lower than the cadmium
containing filler metals, typically in the order of
20-25% in the as cast condition. This means
that the sizes of tungsten carbide that they
will be able to braze successfully are likely
be somewhat less than those than for the
cadmium-bearing filler metals. The general rule
of the tip being less than 10mm in size can
however still be applied.
Tungsten Carbide
reduce their flow properties, which can be best
described as sluggish. They therefore exhibit
limited capacity for capillary flow. Thus to fully
utilise their ability to braze larger sections of
tungsten carbide they need to be pre-placed
in the joint as pieces of foil, as opposed to
being hand fed to the joint. Easy-flo® No. 3
and Argo-braze® 50 find particular use in the
brazing of large diameter rock-drills.
Easy-flo® No. 3 would also be chosen where
tungsten carbide is to be brazed to stainless
steel and the finished joint is likely to be
exposed to a wet or damp service environment
where interfacial corrosion would be a service
hazard. Clearly, in brazing tungsten carbide to
stainless steel a whole set of new rules (due to
the much greater difference in the expansion
coefficients between tungsten carbide and
stainless steel) needs to be applied.
Melting
Zinc % Tin % Gallium % EN 1044
Range ˚C
17 5 3 608-630 Prop
17 5 - 620-655 AG102
22 2 - 630-660 AG103
All three filler metals listed in Table 2 have
relatively low brazing temperatures and free
flowing properties. The general comments
made against the free flowing cadmium-
bearing filler metals are also applicable here.
Filler metal A has a patented and proprietary
composition, and was developed to have a
melting range / brazing temperature close to
that of the cadmium containing filler metals.
Silver-flo® 56 and Silver-flo® 55, while having
marginally higher brazing temperatures than
the cadmium containing filler metals, have been
23
Tungsten Carbide

for many years the accepted replacements for
the first four filler metals in Table 1.
There are of course a number of lower
silver content silver-copper-zinc and silver-
copper-zinc-tin filler metals available that
could potentially be used for the purpose of
brazing tungsten carbide but none appear to
be in common use and hence they are not
included in Table 2. If seeking a less expensive
alternative to the relatively high silver content
filler metals of this group, it is important to
appreciate that while filler metals may be
of a similar composition, their properties,
particularly their ductility, could well be
significantly less.
For example, Silver-flo® 56 and Silver-flo®
55 are both members of the silver-copper-
zinc-tin family and might seem very similar
to a filler metal with only 45% silver and 3%
tin, however, the lower silver content, silver-
copper-zinc-tin filler metals go through a
ductile, brittle transition at about 300C. This
transition could result in cracks forming in the
filler metal on cooling as it tries to dissipate
the cooling stresses. Likewise, while some
silver-copper-zinc filler metals are very ductile,
others are not. A filler metal’s ductility cannot
be assessed just by its silver content, as it
is the combination / percentages of silver,
copper and zinc that determine this property.
If a less expensive product is required then
this should be discussed with a brazing filler
metal supplier, as they will have experience
and knowledge of which products within their
range exhibit the required properties.

Table 3: Nominal compositions of the common cadmium-free nickel and

manganese containing filler metals
Silver Copper Zinc Nickel Manganese Melting
Filler Metal EN 1044
% % % % % Range ˚C

Argo-braze® 502 50 20 28 2 - 670-750

Argo-braze® 49H 49 16 23 4.5 7.5 680-705 AG502

Argo-braze® 49LM 49 27.5 20.5 0.5 2.5 670-710 Prop

Argo-braze® 40 40 30 28 2 - 670-780

Argo-braze® 27 27 39 22 5.5 9.5 680-830 AG503

Argo-braze® 25 25 38 33 2 2 710-810 Prop

= AWS A5.8 BAg-24 = AWS A5.8 BAg-4

The filler metals in Table 3, (or at least the first
4) are the most commonly used for the brazing
of tungsten carbide. In Europe, Argo-braze®
49H is by far the most common, and therefore
can currently be regarded as the ‘standard filler
metal’ used for brazing tungsten carbide. All
the filler metals listed contain nickel, and the
majority also contain manganese. They are
therefore suitable for brazing pieces of tungsten
carbide with dimensions up to 20 mm as well
as those carbides that are more difficult to
wet, due to them having a low cobalt-content,
containing titanium or tantalum carbides, or
free graphite. None of the filler metals are free
flowing and as a general rule need to be pre-
placed in the joint as a foil pre-form to achieve
the best results.
Argo-braze® 49H can be seen as a
replacement for cadmium-containing filler

24

metals, Easy-flo® No. 3 and Argo-braze®
50 in Table 1. However, Argo-braze® 49H is
stronger and less ductile than both of them,
and this can lead to some problems when
moving from one of the cadmium-containing
filler metals to Argo-braze® 49H. The high
strength and lower ductility of this filler metal
can sometimes result in cracking problems in
applications where no such problems existed
when using a cadmium-bearing filler metal. A
solution to such problems can often be found
by using Argo-braze® 502 or Argo-braze®
49LM. Argo-braze® 49H is disliked by some
users due to the finished colour of the filler
metal and its sticky feel when attempting to
move tips around. The solution to both of
these issues is to use Argo-braze® 502. One
advantage that Argo-braze® 49H has over
similar filler metals is that it offers improved
elevated temperature properties. Where most
silver based filler metals tend to start losing
strength at around 200C, Argo-braze® 49H
extends this drop off temperature to around
300C. This can be useful when tools are
being made that could be subject to elevated
temperatures in service.
Argo-braze® 49H is used as the brazing
filler metal in applications ranging from the
manufacture of rock-drills to dental burrs,
lathe tools to mining tools and router bits to
tungsten carbide tipped circular saws. It is
currently the first choice filler metal for most
tungsten carbide brazing applications where
the size of the tip is less than 20 mm. It
would also be the first choice in applications
where the grade of tungsten carbide was
one identified as being difficult to wet, due
to its low cobalt content, having additions of
titanium and or tantalum carbide or where free
graphite was present.
Argo-braze® 502 is free from manganese and
is seen by some to offer certain advantages.
This filler metal is commonly used in the
United States and is listed within the AWS A5.8
Tungsten Carbide
specification (as indicated in Table 3). One
of its main advantages is that it is more free
flowing than Argo-braze® 49H and as a result
is often preferred by operators. It can be used
in most applications where using Argo-braze®
49H would be considered, but as it does not
contain manganese, this would exclude it from
being used on the more difficult to wet grades
of tungsten carbide. Some disadvantage is
also seen due to its slightly higher brazing
temperature.
Argo-braze® 49LM was developed as a
modified version of Argo-braze® 49H for
use in the manufacture of a cadmium-free
tri-metal product. Although it was developed Argo-braze® 49H
specifically for this application, it can be used is the first choice
as a filler metal in its own right. Its lower filler metal for most
nickel and manganese levels compared to tungsten carbide
Argo-braze® 49H result in a filler metal that brazing applications
is less strong and more ductile. In certain where the size of
applications, where cracking problems have the tip is less than
been experienced with Argo-braze® 49H 20 mm… and also
it can provide a solution. Where a tri-metal for applications
product coated with Argo-braze® 49H is being where the grade of
used and a need arises for some additional tungsten carbide
filler metal to be added to the joint then it is difficult to wet,
would be logical to use this filler metal if due to its low
available. However, it is also acceptable to cobalt content,
use Argo-braze® 49H in such circumstances. having additions
Although it is lower in nickel and manganese, of titanium and or
the filler metal still shows improved wetting tantalum carbide or
characteristics over the manganese free filler where free graphite
metals in the table. was present.
Argo-braze® 40 (another AWS A5.8 listed filler
metal) represents a more economic filler metal
for use when brazing tungsten carbide than
the first three filler metals in this table because
it contains only 40% silver. Its nickel content
provides enhanced wetting characteristics and
joint thickening properties making it suitable
for many of the applications where Argo-
braze® 502 might be used. Its main drawback
is its higher brazing temperature, which makes
it less ‘user-friendly’ than the first three filler
25
Tungsten Carbide

metals in Table 3. Nevertheless where a need
exists for a less expensive filler metal then
Argo-braze® 40 would be a good choice.
Argo-braze® 27 was developed as a less
expensive alternative to Argo-braze® 49H.
However, its high brazing temperature and
long melting range make it much less user
friendly than Argo-braze® 49H, and even
though it is a less expensive alternative it is
not extensively employed.
Argo-braze® 25 was originally developed
as a lower cost rock-drill brazing filler
metal. However, the success of the silver-
free copper-zinc-cobalt-manganese filler
metal for the same application means that
currently this filler metal is rarely used. It
provides a less expensive alternative to Argo-
braze® 49H, while still offering very good
wetting characteristics due to its nickel and
manganese contents. Its slightly lower brazing
temperature, narrow melting range and lower
nickel and manganese content mean that it
will flow more freely than Argo-braze® 27 and
therefore may prove somewhat easier to use.

Table 4: Nominal compositions of some specialised silver containing

filler metals

Silver Copper Others Nickel Manganese Melting

Filler Metal EN 1044
% % % % % Range ˚C

Argo-braze® 85 85 - - - 15 960-970 AG501

B* 65 28 - 2 5 750-850 Prop

Argo-braze® 64 64 26 Indium 6 2 2 730-780 Prop

C* 57.5 32.5 Tin 7 - 3 605-730 Prop

* These filler metals currently not available from Johnson Matthey

Argo-braze® 85 was a filler metal originally
suggested for use in applications requiring
the simultaneous heat treatment of a backing
Argo-braze® 85 material, and it was also identified as having
was a filler metal enhanced wetting capabilities on difficult to
originally suggested wet carbides. Additionally, the filler metal has
for use in good elevated temperature properties up to
applications 400oC and can be used in applications where
requiring the joints are exposed to elevated temperature
simultaneous heat conditions in service. However, the filler
treatment of a metal is rarely used as the development
backing material, of copper based filler metals with similar
and it was also brazing temperatures and enhanced elevated
identified as having temperature strength has replaced it.
enhanced wetting
capabilities on Filler metal B and Argo-braze® 64 can or
difficult to wet have been specially formulated for use when
carbides. brazing tungsten carbide items that will be
subject to a Physical Vapour Deposition (PVD)
coating with TiN (titanium nitride) and other
similar types of coating. They contain no
elements such as cadmium and zinc that are
likely to volatilise during the coating process.
The nickel and manganese additions obviously
impart the required characteristics for the
brazing of tungsten carbide, and indium or tin
are used as melting point depressants. Filler
metal B might also be considered for use in
applications where the joints would be subject
to elevated service temperatures.

26
 Tungsten Carbide
Table 5: Nominal compositions of some common copper based brazing
filler metals
Copper Zinc Cobalt Nickel Manganese Others Melting
Filler Metal EN 1044
% % % % % % Range ˚C

Copper 100 - - - - 1083 CU103

B Bronze™ Bal. - - 3 - Boron 0.035 1081-1101 CU105

A Bronze™ 96.9 - - 2.5 - Silicon 0.6 1090-1101 Prop

C Bronze™ 86.85 - - 2.15 11 965-995 Prop

D Bronze™ 86 - 4 - 10 - 980-1030 Prop

J Bronze™ 67.5 - - 9 23.5 - 925-955 Prop

Argentel™ No. 1 60 39.75 - - - Silicon 0.3 875-895 CU301

F Bronze™ 58 38 2 - 2 890-930 Prop

D* 55 35 - 6 4 - 880-920 Prop

E* 54.85 25 - 8 12 Silicon 0.15 855-915 Prop

H Bronze™ 52.5 - - 9.5 38 - 880-920 ▲

Argentel™ 48 42.25 - 9.5 - Silicon 0.25 870-890 CU306

▲ = AMS 4764 * These filler metals currently not available from Johnson Matthey

Pure copper will wet and bond with tungsten
carbide very successfully and together with
brass was one of the first filler metals to be
used for the brazing of tungsten carbide. Its
use today is as an inexpensive filler metal
for reducing atmosphere or vacuum furnace
brazing of tungsten carbide. However, its
natural ability to produce joints with a thin
layer of brazing filler metal limits its use to
applications where small sections of carbide
need to be brazed. A typical application could
be the brazing of tungsten carbide tips into
drills to be sold in the DIY market.
B Bronze™ is another filler metal for use
in reducing atmosphere or vacuum furnace
brazing of tungsten carbide. It was originally
developed to be a filler metal with improved
gap filling properties that could be used
in reducing atmosphere furnace brazing
applications where the joint fits were too large
to use copper. Its nickel and boron additions
give it better wetting characteristics, and will
also allow the formation of joints containing a
thicker layer of brazing filler metal. B Bronze™
has the ability to bridge gaps up to 0.5 mm
and is able to fill joints where spacer wires
or other means have been used to create a
larger controlled joint clearance. This means
that it is possible to braze quite large sections
of tungsten carbide, since it is possible to
produce relatively thick ductile joints with this
filler metal.
A Bronze™ was extensively used for the
brazing of rock-drills and is still used in some
cases for that type of application. It is used in
air with a flux and induction heating. While it
could be used for other applications involving
the brazing of tungsten carbide it has never
been widely used.

27
Tungsten Carbide
C Bronze™ was originally developed to allow
for step or sequential furnace brazing of steel
components, where pure copper was used as
the first step brazing filler metal. The nickel
and manganese contents of this filler metal
make it highly suitable for the brazing of
tungsten carbide, and its melting range makes
it suitable for the brazing and simultaneous
heat treatment of certain grades of steel.
It is used in reducing atmosphere furnace
brazing applications, but due to its manganese
content, low dew point atmospheres must
be used to reduce the manganese oxide and
prevent the formation of further quantities
during the brazing process. It is also used
F Bronze™ is
in vacuum brazing applications, but it needs
another filler
to be used with a partial pressure brazing
metal specifically
technique to suppress the volatilisation of
developed for
the manganese. This filler metal has found
the brazing of
extensive use in the brazing of tungsten
rock-drills, but
carbide tipped drills for use by professional
unlike some of the
trades people, where brazing of the tip and
other filler metals
heat treatment of the shank are carried out in
developed for this
one operation.
purpose it has found
a wider application D Bronze™ is another filler metal specifically
for brazing tungsten developed for the brazing of rock-drills. It has
carbide. found little or no use outside of this area.
J Bronze™ with its high manganese content,
provides filler metal with a lower brazing
temperature, and which is higher in strength
than C Bronze™. Some manufacturers of
professional type tungsten carbide tipped
drills use it in preference to C Bronze™ since
it is said to offer good wear resistance. At
the same time it has a brazing temperature
which matches the heat treatment of the high
strength steel frequently used as the shank
material.
Argentel™ No.1 represents the classic brass
brazing filler metal, a 60-40 copper-zinc filler
metal with a small addition of silicon. This filler
metal tends to be used in the manufacture of
28
low cost, DIY market, tungsten carbide tipped
drills and circular saw blades. Brazing with
this filler metal is often carried out using HF
induction - the filler metal being applied to
the joint in the form of a flux-bearing brazing
paste. Flame brazing using a separate flux
and automatic feeding of the joint with wire
is also widely practiced. Due to the fact that
it produces joints containing a relatively thin
layer of brazing filler metal its use is restricted
to brazing relatively small pieces of tungsten
carbide.
F Bronze™ is another filler metal specifically
developed for the brazing of rock-drills,
but unlike some of the other filler metals
developed for this purpose it has found a
wider application for brazing tungsten carbide.
It is typically applied in air using HF induction
heating and a separate flux. The filler metal is
most commonly pre-placed in the joint as a
main mass and allowed to flow through the
joint. Hand torch brazing is also possible with
this filler metal.
Filler metals D and E are based on the classic
nickel silver / bronze welding filler metal
composition of Argentel™ where an addition
of manganese has been made to the basic
copper-zinc-nickel composition to enhance
their wetting performance. These two filler
metals represent low cost, high strength
materials for torch brazing applications.
H Bronze™ is similar to J Bronze™ but its high
manganese content makes for a lower brazing
temperature. This filler metal is recommended
for use in elevated temperature applications
up to 400C and in the field of brazing tungsten
carbide has been used to produce joints that
will be exposed to such temperature. It has
found use in the brazing of road-planing tools.
Argentel™ is the copper-zinc-nickel-silicon filler
metal widely used for ‘bronze welding’.
 Tungsten Carbide
Table 6: Nominal compositions of the brazing filler metals used on the
common tri-metal products
Silver Copper Zinc Nickel Manganese Melting Core
Filler Metal Other %
% % % % % Range ˚C Material

F* 64 26 - Indium 6 2 2 730-780 Copper

Easy-flo®** 50 15 16 Cadmium 19 - - 620-630 Copper

Easy-flo® No.3 50 15.5 15.5 Cadmium 16 3 - 635-655 Copper

Argo-braze® 502 50 20 28 - 2 - 660-750 Copper

Argo-braze® 49LM 49 27.5 20.5 - 0.5 2.5 670-710 Copper †

G* - 100 - - - - 1083 Nickel ‡

† Also available with copper alloy core and nickel mesh core
‡ With nickel mesh core
** Obsolete alloy for Johnson Matthey
* These filler metals currently not available from Johnson Matthey

The filler metals detailed in Table 6 are those metal with the ability to braze larger sections
that can be found in the form of tri-metal of tungsten carbide.
products, primarily with a copper core and
supplied in a ratio of 1:2:1. The characteristics As indicated in the table, Argo-braze® 49LM
of the individual filler metals have been while commonly supplied with a copper core
covered in the relevant tables above. can also be supplied with a copper alloy
core. The alloy core, often a copper-nickel
By far the most commonly used products these alloy, provides joints with a higher level of
days are the ones coated with Argo-braze® toughness able to cope more adequately with
49LM. The product coated with Filler metal F impact loads in service.
is obviously intended for use in applications
where Physical Vapour Deposition (PVD), TiN
(titanium nitride) coatings or similar are to be
applied to the part. The products coated with
the cadmium containing filler metals, Easy-flo®
and Easy-flo® No.3, are rarely used for the
reasons previously mentioned. The cadmium-
free product coated with Argo-braze® 502
provides a manganese-free alternative to
Argo-braze® 49LM, and is preferred by some
users as it allows for easier movement and
positioning of tips. It is recommended when
using the tri-metal products to move and slide
the tips around when the filler metal is in
the molten condition to reduce flux and gas
entrapment in the joints. Filler metal G with
a nickel mesh core is a furnace brazing filler

29
Tungsten Carbide

Table 7: Specialised noble metal containing filler metals

Silver Copper Gold Palladium Nickel Manganese Silicon Melting

Filler Metal
% % % % % % % Range ˚C

Pallabraze® 1120 75 - - 20 - 5 - 1000-1120

Pallabraze® 830 66.5 24.5 - 5 2 2 - 810-830

Orobraze® 1004 - 31.5 35 10 14 9.5 - 971-1004

H* - 33.5 31 9.75 9.75 16 - 927-949

Orobraze® 1052 - 31 25 15 18 11 - 1017-1052

Orobraze® 1013 - 37 25 15 10 13 - 970-1013

Orobraze® 950 - - 82 - 18 - - 950

Pallabraze® 851 - - - 47 47 - 6 810-851

* These filler metals currently not available from Johnson Matthey

The filler metals listed in Table 7 find use in the tungsten carbide backing of the PCD. This
applications where joints of extremely high was surprising, since palladium is an element
The filler metals strength are required or where the joints known to improve the wetting characteristics
listed in Table 7 find need to exhibit high strength at elevated of filler metals. Modified filler metals, with
use in applications temperatures. Many are patented or have additions of nickel and nickel and manganese
where joints of their applications patented. Some are used were produced and tested. While the nickel
extremely high for making carbide-to-carbide joints, whereas containing filler metal showed an improvement
strength are others are used because they allow for in wetting, the nickel and manganese bearing
required or where simultaneous heat treatment and vacuum filler metal was by far superior.
the joints need brazing of parts. Many of the applications
to exhibit high in which such filler metals are used are
strength at elevated considered confidential so it is not possible
temperatures. Many to provide any specific details or information
of the applications about their uses.
are considered
confidential so Pallabraze® 830 was a filler metal developed
it is not possible for the brazing of PCD’s where the finished
to provide any joints were going to be subject to service at
specific details or elevated temperature. The requirement was
information about for a filler metal to have the lowest possible
their uses. brazing temperature to minimise the damage
to the diamond layer, but have adequate high
temperature properties. Filler metal screening
suggested the standardised silver-copper- 5%
palladium filler metal EN 1044 PD106 would
be a possible candidate. However, when this
was tested it showed very poor wetting on

30
 Tungsten Carbide
Table 8: EN 1045 Flux classes for use when brazing tungsten carbide

For
EN 1045 Temperature Composition
Brazing Comments
Classification Range ˚C Type
Above ˚C
Type FH10 500 to 800 600 Boron Compatible for use with most low
compounds temperature silver brazing filler
metals. Suitable for use in most
Simple &
applications involving the brazing
complex
of tungsten carbide, except in
fluorides
those applications where the
tungsten carbide contains titanium
of tantalum carbides or has a low
cobalt content.

Type FH12 550 to 850 600 Boron Compatible for use with most low
compounds temperature silver brazing filler
metals. Suitable for use in most
Simple &
applications involving the brazing
complex
of tungsten carbide, especially
fluorides with
in those applications where the
the addition
tungsten carbide contains titanium
of elemental
of tantalum carbides, has a low
boron
cobalt content or contains free
graphite.

Type FH20 700 to 1000 750 Boron Compatible for use with the
compounds medium temperature brass and
nickel silver type filler metals. Flux
Fluorides
will not be suitable for brazing
tungsten carbides where titanium
or tantalum carbides are present.
Type FH21 750 to 1000 800 Boron Compatible with the high
compounds temperature copper based filler
metals. Flux will not be suitable for
brazing tungsten carbides where
titanium or tantalum carbides are
present.

Type FH30 +1000 +1000 Boron Compatible with the high

compounds temperature copper based filler
phosphates metals. Flux will not be suitable for
and silicates brazing tungsten carbides where
titanium or tantalum carbides are
present.

31
Tungsten Carbide

How to find out more

Johnson Matthey Metal Joining is a global

supplier of brazing filler metals and fluxes.

If you would like to find out more about

Metal Joining the products and services that we can offer
email Metal Joining on
mj@matthey.com

or visit our website at

www.jm-metaljoining.com

for more information, or contact us on

+ 44(0)1763 253200.

Johnson Matthey plc cannot anticipate all conditions under which this information and our products or the products of other manufacturers in
combination with our products will be used.

This information relates only to the specific material designated and may not be valid for such material used in combination with any other
materials or in any process. Such information is given in good faith, being based on the latest information available to Johnson Matthey Plc and
is, to the best of Johnson Matthey plc’s knowledge and belief, accurate and reliable at the time of preparation. However, no representation,
warranty or guarantee is made as to the accuracy or completeness of the information and Johnson Matthey plc assumes no responsibility
therefore and disclaims any liability for any loss, damage or injury howsoever arising (including in respect of any claim brought by any third
party) incurred using this information. The product is supplied on the condition that the user accepts responsibility to satisfy himself as to the
suitability and completeness of such information for his own particular use. Freedom from patent or any other proprietary rights of any third
party must not be assumed. The text and images on this document are Copyright and property of Johnson Matthey.

This datasheet may only be reproduced as information, for use with or for resale of Johnson Matthey products. The JM logo©, Johnson Matthey
name© and product names referred to in this document are trademarks of Johnson Matthey. Easy-flo® and Silver-flo® are registered to JM in the
EU. Sil-fos™ is registered to JM in the UK and certain other countries but is marketed as Mattiphos™ in Germany and the USA.

32