CHAPTER NO#32

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Overview of Brazing and Soldering
 Both use filler metals to permanently join metal
parts, but there is no melting of base metals
 When to use brazing or soldering instead of fusion
welding:
◦ Metals have poor weldability
◦ Dissimilar metals are to be joined
◦ Intense heat of welding may damage components
being joined
◦ Geometry of joint not suitable for welding
◦ High strength is not required

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Overview of Adhesive Bonding
Uses forces of attachment between a filler material
and two closely spaced surfaces to bond the parts
Filler material in adhesive bonding is not metallic
Joining process can be carried out at room temperature
or only modestly above

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Brazing
Joining process in which a filler metal is melted and
distributed by capillary action between faying surfaces
of metal parts being joined
No melting of base metals occurs
Only the filler melts
Filler metal Tm greater than 450C (840F) but less
than Tm of base metal(s) to be joined
It is achieved by diffusion without fusion
(melting) of the base
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 Brazing Process
1. The joint area is mechanically cleaned and fluxed
 Flux can be applied before the joint is assembled, or
during the brazing process.
2. The joint is assembled.
 May require clamping.

3. A heat source is used to raise the temperature of the

base metal above the melting of the filler metal (>840
o
F).

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Brazing process
4.The filler metal is added to the joint.
5.The filler metal flows into the joint and adheres to the
surfaces.
6.The heat source is removed and the filler metal
solidifies, bonding the surfaces together

◦ Must insure the joint is not overheated.

◦ If this occurs the flux will burn and contaminate the
joint.
◦ When the joint becomes contaminated it must be
recleaned and refluxed before the welding can
continue.

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Advantages of Brazing
 Any metals can be joined including dissimilar metals
 Certain operations are so quickly & automated production
 Some methods allow multiple joints to be brazed
simultaneously
 It can be applied to join thin walled parts that cannot be
welded
 Less power & heat is required
 Problems related to HAZ is less
 Joint areas that are inaccessible can be brazed

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Disadvantages and Limitations of
Brazing
Joint strength is generally less than a welded joint
Joint strength is likely to be less than the base metals
High service temperatures may weaken a brazed joint
Color of brazing metal may not match color of base
metal parts, a possible aesthetic disadvantage

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 Applications
It is widely used in industries including
automotives ,electrical equipment, cutting tools &
jewelry making.
such as production of reliable ceramic-to-metal joints
miscellaneous applications such as fabrication of
food-service dispensers (scoops) used for ice cream
and corrosion-resistant and leak proof joints in
stainless steel blood-cell washers

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Brazed Joints
Brazed joints are of two types: Butt & lap joint
The conventional butt joint provides a limited surface
area for brazing
To increase the faying areas in brazed joint parts are
often scarfed or stepped or altered.
Conventional Butt joint
Scarf joint
Stepped joint
Increased cross section of part at joint

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A scarf joint is made by joining two members having tapered, beveled,
or chamfered ends which lap together, as opposed to a butt joint
where squared ends of the mating members simply butt together.
There are basically only two types of brazed joints, butt and lap, with all
other joints being only modifications. Types of brazed joints, showing flat
(left) and tubular (right) configurations. (a) Butt. (b) Lap. (c) Butt-lap. (d)
Scarf.

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Brazed Joints
Lap joints are widely used in brazing
They provide a large interface area between parts
Filler metal is bonded to the base part throughout
entire interface area
Clearance between mating surfaces must be enough
not to restrict molten filler metal
If clearance is too large then capillary action will be
reduced. Optimum clearance should be present

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 Cleanliness of joint surface is also important
 Surface must be free of oxides, Oils or other
contaminants
 Chemical treatments such as solvent cleaning &
mechanical treatments such as wire brushing, sand
blasting
 Fluxes are also used to maintain surface cleanliness &
promote wetting for capillary action between faying
surfaces
 The ideal clearance for production work is frequently
cited as 0.05–0.13 mm. However, some metals
actually require interference fits, whereas others
require clearances as great as 0.25 mm.

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Filler metals
 Filler metals have following characteristics
1. Melting temperature must be compatible
2. Surface tension must be low for good wettability
3. Fluidity of molten metal for penetration high
4.Metal must be capable of being brazed
5. Chemical & physical interaction with base metal must
be avoided
Filler metals can be wire,rod,sheet,strips,powder & paste
form ,mixed with fluid fluxes & binders

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Brazing fluxes
 Inhibit formation of oxides & other unwanted by
products in brazing processes.
 Good flux include low melting temperature
 Low viscosity
 Facilitate wetting
 Protect the joint
Flux should remove easily after brazing, common
ingredients for flux are borax, fluorides & chlorides.
Wetting agents are also added. without flux brazing
in vacuum is done.

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Some Filler Metals for Brazing
Base metal(s) Filler metal(s)
Aluminum Aluminum and silicon
Nickel-copper alloy Copper
Copper Copper and phosphorous
Steel, cast iron Copper and zinc
Stainless steel Gold and silver

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Filler Metals
Filler material should be chosen
for the specific application.
The criteria for selection should
be:
 Base metals
 Required joint strength
 Joint design
 Cost / Availability
 Appearance
 Corrosion
 Brazing process

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 Applying Filler Metal

Fig: Several techniques for applying filler metal in brazing: (a) torch
and filler rod. Sequence: (1) before, and (2) after.

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 Applying Filler Metal

Figure: Several techniques for applying filler metal in brazing: (b)

ring of filler metal at entrance of gap. Sequence: (1) before, and (2)
after.
Heating Methods in Brazing
 Torch Brazing - torch directs flame against work in
vicinity of joint
 Any joint that can be reached by a torch and brought to
brazing temperature can be readily brazed by this
technique.
 The adjustment of the torch flame is important.
Generally, a slightly reducing flame is desirable.
 In manual torch brazing, the brazing filler metal is usually
face fed in the form of wire or rod, or preplaced.
 To ensure uniform heating throughout the joint, an
important consideration, it may be advisable to use a
multiple-tip torch or more than one torch.
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 Torch brazing can be automated relatively easily.
Usually, such systems involve multiple-station rotary
indexing tables.
 The part is fed into a holding fixture at the first station,
then indexed to one or more preheating stations,
depending on the heating time required.
 A brazing station is next, followed by a cooling station
and an ejection station

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Furnace Brazing
 furnace supplies heat, Furnace brazing is used extensively
 There are two basic types of furnaces used for brazing: the
batch and the continuous.
 for high-production continuous-conveyor-type furnaces
are used. For medium-production work, batch-type
furnaces are best.
 A large volume of furnace brazing is performed in
vacuum, which prevents oxidation and often eliminates
the need for flux. Vacuum brazing has found wide
application in the aerospace and nuclear fields.

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Induction Brazing
 The high-frequency induction heating method for brazing is
clean and rapid
 The heat for induction brazing is created by a rapidly
alternating electric current that is induced into the work piece by
an adjacent coil.
 The work piece is placed in or near a coil carrying alternating
current, which induces the heating current in the desired area.
 Brazing filler metal is normally preplaced in the joint, and the
brazing can be done in air, in an inert atmosphere, or in a
vacuum.
 Induction brazing is well suited for mass production, and
mechanized systems.

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Resistance Brazing
 Heating by electrical resistance in parts
 The process is most applicable to relatively simple joints
in metals that have high electrical conductivity.
 The work pieces are heated locally, and brazing filler
metal that is preplaced between the work pieces is
melted by the heat obtained from resistance to the flow
of electric current through the electrodes and the work.
 In the usual application of resistance brazing, the
heating current, which is normally alternating current,
is passed through the joint itself. Equipment is the same
as that used for resistance welding

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Dip Brazing
 Salt bath or molten metal bath is used for heating.
 Assembled parts are immersed in baths contained in a
heating pot.solidificaation occur after removing from
bath.
 In salt bath molten mixture contains fluxing ingredients
& filler metal is preloaded.
 In metal bath method the molten filler metal is a heating
medium drawn by capillary action Into joint during
submersion.
 Dip brazing is fast heating cycle & can be used to braze
many joints as single or multiple parts

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 INFRARED BRAZING
This method uses heat for a high intensity infrared lamp.
Lamps generate 5000W of radiant energy, which is
directed at work part.
This process is slower & limited also.
Availability of suitable reflectors have made infrared heat
a commercially important generator for brazing.
Lamps are often arranged in a toaster like configuration,
with parts traveling between two banks of lamps.

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BRAZE WELDING
It is used for filling a more conventional joint such s
V joint. A greater quantity of filler metal is deposited
than in brazing & no capillary action occurs.
In this joint consist entirely of filler matal,base metal
does not melt & not fused into joint.
This principle application is in repair work

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Soldering
Joining process in which a filler metal with Tm less
than or equal to 450*C (840F) is melted and
distributed by capillary action between faying surfaces
of metal parts being joined
No melting of base metals, but filler metal wets and
combines with base metal to form metallurgical bond
Soldering similar to brazing, and many of the same
heating methods are used
Filler metal called solder
The solder is precoated called tinning whether solder
contains any tin.

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Clearance b/w range from 0.075 to 0.125mm.
In case of tinned clearance is about 0.025mm.
Most closely associated with electrical and electronics
assembly (wire soldering).they are used to make metallic
joints between conducting wires, films, or contacts.
They are also used for the routine low-temperature joining
of copper plumbing fixtures and other devices.

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Advantages / Disadvantages
Advantages:
Lower energy than brazing or fusion welding
Variety of heating methods available
Good electrical and thermal conductivity in joint
Easy repair and rework
Disadvantages:
Low joint strength unless reinforced by mechanically
means
Possible weakening or melting of joint in elevated
temperature service

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 Joint Designs
Solder joints are also limited to lap and butt joints.
Butt joint is not used in load bearing application but
special part geometries in electrical connection.
For mechanical joints sheets edges are bent to increase
strength or by making the large surface area to provide
maximum support by solder.
In electronics soldering give conductive path, heat
generation & vibration

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Solders
Most solders are alloys of tin & lead both metals have
low melting point.
Lead is poisonous & used minimized.tin is chemically
active & promote wetting action.
Copper in electrical connection used, silver &
antimony is also used
Lead free solders are becoming important.

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Functions of Soldering Fluxes
Be molten at soldering temperatures
Remove oxide films and tarnish from base part surfaces
Prevent oxidation during heating
Promote wetting of faying surfaces
Be readily displaced by molten solder during process
Leave residue that is non-corrosive and nonconductive.
Unfortunately there is no single flux that serves all.
Inorganic & organic fluxes are made.

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 Soldering Methods
Many soldering methods same as for brazing, except less
heat and lower temperatures are required
These methods include also like brazing
torch, furnace, induction, resistance,dip and infrared
soldering
Other methods are
Hand soldering
Wave soldering
Reflow soldering

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 Hand soldering
It is performed manually using a soldering iron.
A soldering bit made of copper is the working end of a
soldering iron
Its functions are
1. To deliver heat to the parts being soldered
2. To melt solder
3. To convey molten solder to the joint
4. To withdraw excess solder
For fast heating soldering guns are made actuated by
trigger & capable of joint in second
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 Wave soldering
It is a mechanized technique that allows multiple lead wires
to be soldered to a PCB as it passes over a wave of molten
solder.
The processing steps for PCB are
1. Flux is applied using foaming, spraying or brushing
2. Preheating to evaporate solvents, flux & raise temperature of
assembly.
3. Liquid solder is pumped from a molten pump through slit
onto bottom of board.

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 Wave Soldering

Figure: Wave soldering, in which molten solder is delivered up through a

narrow slot onto the underside of a printed circuit board to connect the
component lead wires.
Reflow soldering
To assemble surface mount components on PCB.
A solder paste consisting of solder powders in a flux
binder is applied to spots on the board
where electrical contacts are to be made between
surface mount components & copper circuit. Board
heated to melt solder
In vapor phase reflow an inert fluorinated
hydrocarbon liquids vaporized by heating in an oven.

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It is subsequently condensed on the board surface
where it transfer heat to melt the solder paste & form
joints on PCB.
In infrared reflow soldering heat from an infrared
lamp is used to melt the solder paste & form joints.
Heating methods to reflow the solder paste include
hot plates, hot air & laser.

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Adhesive Bonding
Joining process in which a filler material is used to
hold two (or more) closely spaced parts together by
surface attachment
Used in a wide range of bonding and sealing
applications for joining similar and dissimilar
materials such as metals, plastics, ceramics, wood,
paper, and cardboard
Considered a growth area because of opportunities
for increased applications

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Adhesive Bonding
Filler material that bind the parts together is the
adhesive non-metallic substance usually a polymer.
The parts being joined are called adherents.
Adhesives are cured by various mechanisms.
Curing refers to the process by which the adhesive’s
physical properties are changed from liquid to solid to
accomplish the surface attachment.
The chemical reaction may involve polymerization,
condensation or vulcanization.

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The curing or hardening of adhesives take time called
curing or setting time. The strength is linked
1. Chemical bonding
2. Physical interaction
3. Mechanical interlocking
For adhesion mechanisms following conditions must prevails
1. Surface of adherents must be clean
2. Wetting of adherents
3. A slightly roughened surface

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Joint Design
Adhesive joints are not as strong as welded, brazed,
or soldered joints
Joint contact area should be maximized
Adhesive joints are strongest in shear and tension
Joints should be designed so applied stresses are of
these types
Adhesive bonded joints are weakest in peeling
Joints should be designed to avoid these types of
stresses

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Some joint design combine adhesive bonding to increase
strength. For example the combination of adhesive
bonding and spot welding is called weld bonding.
Adherend materials ceramics, glass, plastics, wood,
rubber, cloth, paper & cardboard. Some joint designs for
adhesive bonding: (a) through (d) butt joints; (e)
through (f) T‑joints; (b) and (g) through (j) corner
joints.

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 Adhesives types
Natural: plants & animals including gum, starch, soyflour &
collagen. Limited to low stress applications such as cardboard
cartons, furniture & bookbinding.
Inorganic adhesives include sodium silicate & Mg oxychloride.
Synthetic adhesives include a variety of thermoplastic &
thermosetting plastics. They are cured by different mechanism.
Mixing a catalyst & reactive agent
Heating to initiate chemical reaction
Radiation curing
Curing by evaporation of water from liquid or paste adhesives

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 Surface preparation
Strength of bond depends on the degree of adhesion
between adhesive & adherend
For metals solvent wiping & for nonmetals solvent
cleaning is generally used.
Adhesive bonding should accomplish as soon as possible
due to dirt accumulation.

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Application Methods

Brushing: performed manually, uses a stiff-bristled brush. Coatings

are often uneven.
Flowing: using manually operated pressure-fed flow guns, has more
consistent control than brushing.
Manual rollers: similar to paint rollers, are used to apply adhesive
from a flat container.
Spraying: uses an air-driven (or airless) spray gun for fast
application over large or difficult-to-reach areas.
Automatic application: include various automatic dispensers and
nozzles for use on medium-and high-speed production applications.

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Roll coating: is a mechanized technique in which a rotating roller is
partially submersed in a pan of liquid adhesive and picks up a coating
of the adhesive, which is then transferred to the work surface.

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Limitations of Adhesive Bonding
Joints generally not as strong as other joining methods
Adhesive must be compatible with materials being
joined
Service temperatures are limited
Cleanliness and surface preparation prior to
application of adhesive are important
Curing times can limit production rates
Inspection of bonded joint is difficult