BRAZING &

SOLDERING
PROCESSES
Brazing
 Brazing is a method of joining two metal work pieces
by means of a filler material at a temperature above its
melting point but below the melting point of either of
the materials being joined.

 Flow of the molten filler material into the gap between

the work pieces is driven by the capillary force. The
filler material cools down and solidifies forming a
strong metallurgical joint, which is usually stronger
than the parent (work piece) materials.

 The parent materials are not fused in the process.

Brazing
 Brazing is similar to Soldering. The difference is in the
melting point of the filler alloy: brazing filler materials
melt at temperatures above 840°F (450°C); soldering
filler materials (solders) melt at temperatures below
this point.

 The difference between brazing and welding processes

is more sufficient: in the welding processes edges of
the work pieces are either fused (with or without a
filler metal) or pressed to each other without any filler
material; brazing joins two parts without melting them
but through a fused filler metal.
Surface cleaning and brazing fluxes
 Capillary effect is achieved by both: a proper
Surface preparation and use of a flux for wetting and
cleaning the surfaces to be bonded.

 Contaminants to be removed from the part surface are:

mineral oils, miscellaneous organic soils, polishing and
buffing compounds, miscellaneous solid particles, oxides,
scale, smut, rust.
 The work pieces are cleaned by means of
mechanical methods, soaking cleaning and chemical cleanin
g (acid etching)
.
Surface cleaning and brazing fluxes
 A brazing flux has a melting point below the melting point
of the filler metal, it melts during the heating stage and
spreads over the joint area, wetting it and protecting the
surface from oxidation.

 It also cleans the surface, dissolving the metal oxides.

It is important that the surface tension of the flux is:
 Low enough for wetting the work piece surface;
 Higher than the surface tension of the molten filler metal in order
to provide displacement of the flux by the fused brazing filler.
The latter eliminates the flux entrapment in the joint.
 The flux is applied onto the metal surface by brushing, dipping
or spraying.
 Brazing filler materials
 Copper filler alloys: BCuP-2 (Cu-7P), BCuP-4 (Cu-6Ag-7P).
 Used for brazing Copper alloys, steels, Nickel alloys.

 Aluminum filler alloys: Al-4Cu-10Si, Al-12Si, Al-4Cu-10Si-10Zn, 4043 (Al-

5.2Si), 4045 (Al-10Si).
 Used for brazing Aluminum alloys.

 Magnesium filler alloys: BMg-1 (Mg-9Al-2Zn), BMg-2 (Mg-12Al-5Zn).

 Used for brazing Magnesium alloys.

 Nickel filler alloys: BNi-1 (Ni-14Cr-4Si-3.4B-0.75C), BNi-2 (Ni-7Cr-4.5Si-

3.1B-3Fe), BNi-3 (Ni-4.5Si-3.1B).
 Used for brazing Nickel alloys, cobalt alloys, Stainless steels.

 Silver filler alloys: BAg-4 (40Ag-30Cu-28Zn-2Ni), BAg-5 (45Ag-30Cu-

25Zn), BAg-6 (50Ag-34Cu-16Zn), BAg-7 (56Ag-22Cu-17Zn-5Sn).
 Used for most of metals and alloys except aluminum and magnesium alloys.
Brazing methods
 Torch brazing utilizes a heat of the flame from a
torch. The torch mixes a fuel gas with Oxygen or
air in the proper ratio and flow rate, providing
combustion process at a required temperature.
 The torch flame is directed to the work pieces with a
flux applied on their surfaces.
 When the work pieces are heated to a required
temperature, filler alloy is fed into the flame.
 The filler material melts and flows to the gap between
the joined parts.
 Torch brazing is the most popular brazing method.
Torch brazing
 Torch brazing equipment:
- Fuel gas cylinder with pressure regulator;
- Oxygen cylinder with pressure regulator;
- Welding torch;
- Blue oxygen hose;
- Red fuel gas hose;
- Trolley for transportation of the gas cylinders.
Brazing methods
 Furnace brazing uses a furnace for heating the work pieces.
 Vacuum brazing is a type of furnace brazing, in which heating is
performed in vacuum.
 Induction brazing utilizes alternating electro-magnetic field of
high frequency for heating the work pieces together with the flux
and the filler metal placed in the joint region.
 Resistance brazing uses a heat generated by an electric current
flowing through the work pieces.
 Dip brazing is a brazing method, in which the work pieces together
with the filler metal are immersed into a bath with a molten salt.
The filler material melts and flows into the joint.
 Infrared brazing utilizes a heat of a high power infrared lamp.
Advantages of brazing
 Low thermal distortions and residual stresses in the
joint parts;
 Microstructure is not affected by heat;
 Easily automated process;
 Dissimilar materials may be joined;
 High variety of materials may be joined;
 Thin wall parts may be joined;
 Moderate skill of the operator is required.
Disadvantages of brazing
 Careful removal of the flux residuals is required in
order to prevent corrosion;
 No gas shielding may cause porosity of the joint;
 Large sections cannot be joined;
 Fluxes and filler materials may contain toxic
components;
 Relatively expensive filler materials.
SOLDERING
Soldering
 Soldering is a method of joining two metal work
pieces by means of a third metal (solder) at a
relatively low temperature, which is above the
melting point of the solder but below the melting
point of either of the materials being joined.

 Flow of the molten solder into the gap between the

work pieces is driven by the capillary force.

 The solder cools down and solidifies forming a

joint. The parent materials are not fused in the
process.
Soldering
 Soldering is similar to Brazing. The difference is in the
melting point of the filler alloy: solders melt at temperatures
below 840°F (450°C); brazing filler materials melt at
temperatures above this point.

 The difference between soldering and welding processes is

more sufficient: in the welding processes edges of the work
pieces are either fused (with or without a filler metal) or
pressed to each other without any filler material; soldering
joins two parts without melting them but through a soft low
melting point solder.

 Soldering joints have relatively low tensile strength of

about 10000 psi (70 MPa).
Surface cleaning and soldering
fluxes
 Capillary effect is achieved by both: a proper
Surface preparation and use of a flux for wetting and
cleaning the surfaces to be bonded.

 Contaminants to be removed from the part surface are:

mineral oils, miscellaneous organic soils, polishing and
buffing compounds, miscellaneous solid particles, oxides,
scale, smut, rust.
 The work pieces are cleaned by means of mechanical
methods, soaking cleaning and chemical cleaning (acid
etching).
Surface cleaning and soldering
fluxes
 A soldering flux has a melting point below the melting
point of the solder, it melts during the preheating stage
and spreads over the joint area, wetting it and
protecting the surface from oxidation. It also cleans the
surface, dissolving the metal oxides.

 It is important that the surface tension of the flux is:

 Low enough for wetting the work piece surface;
 Higher than the surface tension of the molten solder in
order to provide displacement of the flux by the fused
solder. The latter eliminates the flux entrapment in the
joint.
Surface cleaning and soldering
fluxes
 The flux is applied onto the metal surface by
brushing, dipping, spraying, in form of a gas-flux
foam or by a flux wave (flowing flux forms a wave
and the printed circuit board moves over the apex
of the wave).

 Flux is acidic therefore its residuals may cause

corrosion if not removed.
Tin-lead solders
 Traditional lead containing solders consist of tin (Sn)
and lead (Pb).

 The most popular alloy in this group is eutectic

composition 63Sn-37Pb (commonly called 63/37).
 The melting point of this alloy is lowest of all Sn-Pb alloys:
361°F (183°C).
 This solder is used for joining electronic components, to
which minimum heat may be applied (computers,
telecommunication devices).
 The 63/37 alloy may be modified by addition of 1.4% of
silver (Ag) for improvement of the joint Creep resistance.
Tin-lead solders
 Low tin solders such as 5Sn-95Pb (5/95), 10Sn-90Pb
(10/90), 15Sn-85Pb (15/85) are used mainly for
sealing containers and radiators, joining and coating
metal parts working at increased temperatures (above
250°F/121°C).

 The alloy 70Sn-30Pb (70/30) is used for coating parts

before soldering.
The advantages of tin-lead alloys:
 Non-expensive;
 Simple equipment (soldering iron, torch);
 Low skill of operator is enough;
 Low melting point.
 The main disadvantage of these alloys is toxicity of
lead.
Lead-free solders
 Most of lead-free solders are tin base alloys: 96.5Sn-
3Ag-0.5Cu, 99.3Ag-0.7Cu, 95Sn-5Sb.

 The alloy 96.5Sn-3Ag-0.5Cu has a composition very close

to the eutectic. Its melting point is 423°F (217°C).
 Fatigue strength of the alloy is similar to that of SnPb
solders, however its wettability is poorer.
 Addition of 1-3% of bismuth (Bi) to the alloy improves its
wettability and decreases the melting point but the fatigue
resistance deteriorates.
 The alloy is now used for wave soldering, reflow and hand
soldering.
Lead-free solders
 The alloy 99.3Ag-0.7Cu with the melting point 441°F
(227°C) is low a cost alternative of the silver
containing alloy. It is used for wave soldering.
 When a low melting point is required, the alloy 42Sn-
58Bi is used. Its melting point is 280°F (138°C).
 Fatigue strength, tensile strength and ductility of the
alloy are relatively low but may be improved by some
addition of silver (Ag).
 The melting point of the alloy 95Sn-5Sb is 450°F
(232°C). The solder is used in the plumbing works.
Soldering methods
 Hand soldering
 Iron soldering utilizes a heat generated by a soldering iron.
 Torch soldering utilizes a heat of the flame from a torch.
 The torch mixes a fuel gas with oxygen or air in the proper ratio
and flow rate, providing combustion process at a required
temperature.
 The torch flame is directed to the work pieces with a flux applied
on their surfaces.
 When the work pieces are heated to a required temperature,
solder is fed into the joint region.
 The solder melts and flows to the gap between the joined parts.
 Hand soldering is used in repair works and for low volume
production.
Soldering methods
 Wave soldering
 The method uses a tank full with a molten solder. The solder is
pumped, and its flow forms a wave of a predetermined height.
The printed circuit boards pass over the wave touching it with
their lower sides.
The method is used for soldering through-hole components on
printed circuit boards.

 Reflow soldering
 In this method a solder paste (a mix of solder and flux particles)
is applied onto the surface of the parts to be joined and then are
heated to a temperature above the melting point of the solder. The
process is conducted in a continuous furnace, having different
zones: preheating, soaking, reflow and cooling. The joint forms
when the solder cools down and solidifies in the cooling zone of
the furnace.
Advantages of soldering
 Low power is required;
 Low process temperature;
 No thermal distortions and residual stresses in the joint
parts;
 Microstructure is not affected by heat;
 Easily automated process;
 Dissimilar materials may be joined;
 High variety of materials may be joined;
 Thin wall parts may be joined;
 Moderate skill of the operator is required.
Disadvantages of brazing
 Careful removal of the flux residuals is required in
order to prevent corrosion;
 Large sections cannot be joined;
 Fluxes may contain toxic components;
 Soldering joints can not be used in high
temperature applications;
 Low strength of joints.