Brazing, Soldering, Adhesive, Bonding

& Mechanical Fastening process

Chapter 30
 Brazing
• Joining process

• A filler metal is placed between two

workpieces and heated until melted

• Two main types of Brazing

– Ordinary
– Braze welding

• Use of flux is very important

 Filler Metals
• Available in a wide range of brazing temperatures

• They come in a wide range of shapes

• Choice of the filler metal and its composition are important

• Diffusion of the filler metal in to the workpeice is an important

consideration

Fig: a) Brazing b) Braze welding operation

 Fluxes

• The use of flux in brazing is very important

• Generally made of:

– Borax
– Boric acid
– Borates
– Fluorides
– Chlorides

• Wetting agents may also be added

 Brazing Methods
• Torch Brazing

– Performed by heating the joint with a torch

– Depositing the filler metal in the joint

– Suitable part thickness (0.25 – 6.0)mm

– Not a automated process

– More than one torch can be used in this process

 Brazing Methods
• Furnace Brazing
– Precleaned & Preloaded with brazing metal
– Heated in a furnace

Fig:An example of furnace brazing a)before b) after

 Other Types Of Brazing

• Induction Brazing

• Resistance Brazing

• Dip Brazing

• Infrared Brazing

• Diffusion Brazing
 Braze Welding

• Prepared like fusion welding

• Filler metal is deposited at the joint with the use of an

oxyacetylene torch

• Considerably more filler is used

• Temperature is minimal compared to that of fusion

welding; part distortion is minimal
 Brazing Process Capabilities
• Dissimilar metals can be assembled with good joint strength

• Shear strength of brazed joints can reach 800Mpa

Fig:Joint Designs commonly used in brazing operations.The clearance between the two parts being brazed is
an important factor in joint strength.If the clearance is to small, the molten braze metal will not fully
penetrate the interface.
Good/Poor Designs
 Soldering
• Different types of soldering

– Torch
– Furnace
– Iron
– Induction
– Resistance
– Dip
– Infrared
– Ultrasonic
– reflow (paste)
– Wave
 Reflow Soldering

• Solvents present in the paste are evaporated

• The Flux in the paste is activated and the fluxing

action occurs

• The components are carefully preheated

• The solder particles are melted and wet the joint

• The assembly is cooled

 Wave Soldering
• Popular approach to attaching circuits to circuit boards

Fig: a)Screening or stenciling paste onto a printed circuit

board: 1) Stenciling process 2) a section of a typical
stencil pattern b) wave soldering process
 Types Of Fluxes

• Inorganic acids or salts

– clean the surface
rapidly

• Noncorrosive resin-
based – used in
electrical applications

• Soldering is used
extensively in
electronics industry
 Adhesive Bonding

• Products are joined and assembled by the use of

Adhesives

• Adhesives properties to be considered

– Strength
– Toughness
– Resistance to various fluids
– Ability to wet the surface to be bonded
 Types of adhesives

Surface must be clean for joining parts

• Should avoid joints that might be subjected to peeling forces

• Design for adhesive bonding
 Adhesive Peeling Test

Fig : Characteristic behavior of (a) brittle (b) tough adhesive in a peeling test
Joint Design in Adhesive Bonding

Fig:Various joint design in adhesive bonding.

Configurations for adhesive bonds

Fig : (a) single lap (b) double lap (c) scarf (d) strap
 Mechanical Fastening
• Threaded Fasters
– Bolts
– Screws
– Nuts

• Other Fastening Methods

– Stapling
– Crimping
– Snap-in Fasteners
– Shrink and press fits
 Rivets

Fig:a)solid b)tubular c) split (bifurcated) d) compression

Fig : Design guidelines for riveting (a)Exposed shank is too long; the result is buckling instead of upsetting
(b)Rivets should be placed sufficiently far from edges to avoid stress concentrations (c)Joined sections
should allow ample clearance for riveting tools (d) section curvature should not interfere with the
riveting process
 Joining Plastics
• Heat softens the plastic to a molten state

• Then pressure added & fusion takes place

• External Heat Sources

– Hot air
– Heated tools & dies
– Electrical-Resistance
– Lasers

• Internal Heat Sources

– Ultrasonic welding
– Friction welding
THE END