BRAZING
Brazing is a metal-joining process in which two or more metal items
are joined together by melting to 450℃ or more and flowing a filler
metal into the joint via capillary action.
This process is called capillary attraction.
The melting point of the filler metal is lower than the adjoining metal.
1
BRAZING
2
FILLER METALS
Most commonly used filler metal: Spelter
50-60% Cu + 40% Zn + 1% Ni + 0.7 % Fe and traces of Si and Mn
Available in the forms of rod, Spelter composition
strip, wire and powder.
Silver brazing filler metal:
30-55% Ag
15-35% Cu
15-28% Zn
18-24% Cd
2-3% Ni or 5% Sn.
Cu Zn Ni Fe
3
STEPS FOR BRAZING
STEP 1: GOOD FIT AND PROPER CLEARANCES
STEP 2: CLEANING THE METALS
STEP 3: FLUXING THE PARTS
STEP 4: ASSEMBLY FOR BRAZING
STEP 5: BRAZING THE ASSEMBLY: HEATING
METHODS
STEP 6: CLEANING THE BRAZED JOINT
4
PROPERTIES OF BRAZING
Workpieces should be free from oxides.
Dissimilar metals can be joined with considerable strength.
Metal properties of the base parts will not be in a disturbed condition.
The brazing joints do not require much finishing.
Brazing can withstand precise dimensions.
Brazing allows for thin metals to join with thicker metals.
Brazing allows for metals and ceramics to be joined.
Less stress on the work given the lower temperatures. 5
FLUXES
Borax and boric acid are
commonly used fluxes for
brazing with copper base
filler metals.
Many other commercial fluxes may be available in
the form of paste or liquid solution leading to:
• ease of application
• adherence to the surface in any position.
6
TYPES OF BRAZING
Two types of brazing techniques:
1. Localised heating techniques
Torch Brazing
Induction Brazing
2. Diffused heating techniques
Dip Brazing
Furnace Brazing
7
TYPES OF BRAZING
1. TORCH BRAZING
Oxy-acetylene flame (3480℃) with neutral (1 : 1) or
reducing flame (0.9 : 1) .
Filler metal may be either preplaced in form of washers, rings,
formed strips, powders or may be fed manually in form of
rod.
8
TYPES OF BRAZING
2. INDUCTION BRAZING
• Heat is generated by induced current into the workpiece
from a water-cooled coil which surrounds the workpiece.
• High frequencies employed - 5 to 400 kHz.
• Clean and rapid.
• Great control and precision.
9
TYPES OF BRAZING
3. DIP BRAZING
Entire assembly is immersed into bath of molten braze alloy
or molten flux.
Preplaced preform melts and fills the joint.
10
TYPES OF BRAZING
4. FURNACE BRAZING
Assembly with preplaced filler metal is placed inside
electrically heated furnace with temperature control for
heating and cooling.
Protective atmosphere with inert gases like argon and helium
or vacuum used.
11
DIFFERENCE BETWEEN
BRAZING AND WELDING
1. In brazing, only the filler metal is melted above the melting
point unlike in welding where both filler metal and base metal
are melted.
2. In welding, high temperatures are needed. Whereas, in
brazing low temperatures enough to melt the filler metal are
needed.
12
APPLICATIONS OF BRAZING
1. Fastening of pipe fittings, tanks,
carbide tips on tools, radiators, axles
etc.
2. To join parts of bicycle such as frame
and rims.
3. To join cast metals to wrought metals,
dissimilar metals and also porous metal
components
4. To join ceramics- active metal welding
5. Suitable for automation. Economical
and accurate.
6. Ray- Ban sunglasses. Strong. Thin
metal. Automation. 13
GATE QUESTIONS
1. Under optimal conditions of the process the temperatures
experienced by a copper work piece in fusion welding, brazing and
soldering are such that
(A) Twelding>Tsoldering>Tbrazing
(B) Tsoldering>Twelding>Tbrazing
(C) Tbrazing>Twelding>Tsoldering
(D) Twelding>Tbrazing>Tsoldering
14
GATE QUESTIONS
1. Under optimal conditions of the process the temperatures
experienced by a copper work piece in fusion welding, brazing and
soldering are such that
(A) Twelding>Tsoldering>Tbrazing
(B) Tsoldering>Twelding>Tbrazing
(C) Tbrazing>Twelding>Tsoldering
(D) Twelding>Tbrazing>Tsoldering
15
GATE QUESTIONS
2. The filler metal used in brazing has melting point of
above
A) 200°C
B) 300°C
C) 420°C
D) 520°C
16
GATE QUESTIONS
2. The filler metal used in brazing has melting point of
above
A) 200°C
B) 300°C
C) 420°C
D) 520°C
17
GATE QUESTIONS
3. The commonly used flux in brazing is
A) Borax
B) Rosin
C) Lead sulphide
D) Zinc chloride
18
GATE QUESTIONS
3. The commonly used flux in brazing is
A) Borax
B) Rosin
C) Lead sulphide
D) Zinc chloride
19
GATE QUESTIONS
4. Which of the following is function(s) of flux used in
brazing?
i. Protect surface from oxidation
ii. Reduce surface tension of filler
iii. Assist its penetration
A) i only
B) ii only
C) i and ii
D) i, ii and iii
20
GATE QUESTIONS
4. Which of the following is function(s) of flux used in
brazing?
i. Protect surface from oxidation
ii. Reduce surface tension of filler
iii. Assist its penetration
A) i only
B) ii only
C) i and ii
D) i, ii and iii
21
GATE QUESTIONS
5. The strength of a brazed joint:
(A) Decrease with increase in gap between the two joining
surfaces
(B) Increase with increase in gap between the two joining
surfaces
(C) Decrease up to certain gap between the two joining
surfaces beyond which it increases
(D) Increases up to certain gap between the two joining
surfaces beyond which it decreases
22
GATE QUESTIONS
5. The strength of a brazed joint:
(A) Decrease with increase in gap between the two joining
surfaces
(B) Increase with increase in gap between the two joining
surfaces
(C) Decrease up to certain gap between the two joining
surfaces beyond which it increases
(D) Increases up to certain gap between the two joining
surfaces beyond which it decreases
23
