Experiment-4: Study of Soldering and Brazing Process.
AIM: To join circuits by soldering and two sheets by brazing process.
EQIPMENT AND MATERIAL REQUIRED:
Oxy-acetylene torch, flux, filler rod, GI sheets 150x150x1mm
TOOLS REQUIRED: Wire brush, hand gloves, chipping hammer, spark lighter.
SOLDERING:
In soldering, the surfaces to be joined are first cleaned, the components assembled or fixture,
and a low-melting-point nonferrous metal (filler metal) is then melted, drawn into the space
between the two solids by capillary action, and allowed to solidify.
Soldering is a brazing-type operation where the filler metal has a melting temperature (or
liquidus temperature if the alloy has a freezing range) below 450°C (840°F). It is typically used
for joining thin metals, connecting electronic components, joining metals while avoiding
exposure to high elevated temperatures, and filling surface flaws and defects.
Flux is the substance added to the metal surface to stop the formation of any oxides or similar
contaminants that are formed during the soldering and brazing processes. The flux increases
both the flow of the filler metal and its ability to stick to the base metal.
BRAZING:
Brazing is the permanent joining of similar or dissimilar metals or ceramics (or composites
based on those two materials) through the use of heat and a filler metal whose melting
temperature (actually, liquidus temperature) is above 450°C (840°F) but below the melting
point (or solidus temperature) of the materials being joined.
DESCRIPTION:
Brazing is coalescence of a joint with the help of a filler metal whose melting temperature is
4500C and is below solidify temperature of the base metal. The filler metal is drawn into the
joint by means of capillary action.
PROCEDURE:
1. The surface to be joined is cleaned properly.
2. Sheets are joined and laid by giving proper clearance.
3. Flux is applied to the joint.
4. Joint is to be heated by using welding torch to heat the filler metal to its melting temperature
when the filler material is placed at the joint.
5. The filler material is flown into the service by capillary action and joint is made.
PRECAUTIONS:
1. As the filler metal fills the joint by capillary action, give only needed clearance.
2. See that the joints are extremely clean.
RESULT:
Two sheets are joined using brazing process.
ADVANTAGES & DISADVANTAGES OF SOLDERING AND BRAZING:
ADVANTAGES OF SOLDERING AND BRAZING:
▪ Low temperature. Since the base metal does not have to melt, a low-temp heat source can
be used. This minimized distortion and created a smaller heat-affected zone (HAZ).
▪ Joints can be made be permanently or temporarily. Since the base metal is not damaged,
parts can be dis-assembled at any time by simply supplying heat. The parts then can be
reused. The joint made by soldering or brazing process is solid enough to be permanent.
▪ Metals of dissimilar can be joined. By using soldering and brazing process dissimilar
metals can be easily joined, such as aluminum to brass, copper to steel and cast iron to
stainless steel. It is also possible to join nonmetals, i.e., ceramics can be easily brazed to
each other or to metals.
▪ Speed of joining. Parts can be pre-assembled, and furnace soldered or brazed in large
quantities. A lower temperature means less time in heating.
▪ Less chance of damaging parts. A heat source can be used that has a maximum
temperature below that which may cause damage to the base material.
▪ Parts of varying thickness can be joined. Very thin parts or a thick part and a thin part can
be easily joined without burning through or overheating them.
▪ Easy realignment. Parts can be easily realigned by reheating the joint, re-positioning the
parts and allowing the filler metal to solidify.
DISADVANTAGES OF SOLDERING AND BRAZING:
▪ Low Strength
▪ Damaged under high temperature conditions.
