Brazes

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Brazes

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Brazes
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Brazes

There are three main categories of torch brazing in use: [10] manual, machine, and automatic torch brazing. Manual torch brazing is a procedure where the heat is applied using a gas flame placed on or near the joint being brazed.

The torch can either be hand held or held in a fixed position depending on whether the operation is completely manual or has some level of automation.

Manual brazing is most commonly used on small production volumes or in applications where the part size or configuration makes other brazing methods impossible.

The use of flux or self-fluxing material is required to prevent oxidation. Torch brazing of copper can be done without the use of flux if it is brazed with a torch using oxygen and hydrogen gas, rather than oxygen and other flammable gases.

Machine torch brazing is commonly used where a repetitive braze operation is being carried out. This method is a mix of both automated and manual operations with an operator often placing brazes material, flux and jigging parts while the machine mechanism carries out the actual braze.

The use of flux is also required for this method as there is no protective atmosphere, and it is best suited to small to medium production volumes.

Automatic torch brazing is a method that almost eliminates the need for manual labor in the brazing operation, except for loading and unloading of the machine.

The main advantages of this method are: a high production rate, uniform braze quality, and reduced operating cost. The equipment used is essentially the same as that used for Machine torch brazing, with the main difference being that the machinery replaces the operator in the part preparation.

Furnace brazing is a semi-automatic process used widely in industrial brazing operations due to its adaptability to mass production and use of unskilled labor.

There are many advantages of furnace brazing over other heating methods that make it ideal for mass production. One main advantage is the ease with which it can produce large numbers of small parts that are easily jigged or self-locating.

Common atmospheres used include: inert, reducing or vacuum atmospheres all of which protect the part from oxidation. Some other advantages include: low unit cost when used in mass production, close temperature control, and the ability to braze multiple joints at once.

Furnaces are typically heated using either electric, gas or oil depending on the type of furnace and application.

However, some of the disadvantages of this method include: high capital equipment cost, more difficult design considerations and high power consumption.

There are four main types of furnaces used in brazing operations: batch type; continuous; retort with controlled atmosphere; and vacuum.

A batch type furnace has relatively low initial equipment costs, and can heat each part load separately. It can turned on and off at will, which reduces operating expenses when it's not in use.

These furnaces are suited to medium to large volume production, and offer a large degree of flexibility in type of parts that can be brazed.

Continuous type furnaces are best suited to a steady flow of similar-sized parts through the furnace.

It is common to use either controlled atmosphere or pre-applied flux in continuous furnaces. In particular, these furnaces offer the benefit of very low manual labor requirements and so are best suited to large scale production operations.

Retort-type furnaces differ from other batch-type furnaces in that they make use of a sealed lining called a "retort". The retort is generally sealed with either a gasket or is welded shut and filled completely with the desired atmosphere and then heated externally by conventional heating elements.

Retort furnaces are often either used in a batch or semi-continuous versions. Vacuum furnaces is a relatively economical method of oxide prevention and is most often used to braze materials with very stable oxides aluminum , titanium and zirconium that cannot be brazed in atmosphere furnaces.

Vacuum brazing is also used heavily with refractory materials and other exotic alloy combinations unsuited to atmosphere furnaces. Due to the absence of flux or a reducing atmosphere, the part cleanliness is critical when brazing in a vacuum.

The three main types of vacuum furnace are: single-wall hot retort, double-walled hot retort, and cold-wall retort.

Typical vacuum levels for brazing range from pressures of 1. Silver brazing , sometimes known as a hard soldering , is brazing using a silver alloy based filler.

These silver alloys consist of many different percentages of silver and other metals, such as copper, zinc and cadmium.

Brazing is widely used in the tool industry to fasten " hard metal " carbide, ceramics, cermet, and similar tips to tools such as saw blades.

Pretinning gets around the problem that hard metals are difficult to wet. Brazed hard metal joints are typically two to seven mils thick. The braze alloy joins the materials and compensates for the difference in their expansion rates.

It also provides a cushion between the hard carbide tip and the hard steel, which softens impact and prevents tip loss and damage—much as a vehicle's suspension helps prevent damage to the tires and the vehicle.

Finally, the braze alloy joins the other two materials to create a composite structure, much as layers of wood and glue create plywood.

The standard for braze joint strength in many industries is a joint that is stronger than either base material, so that when under stress, one or other of the base materials fails before the joint.

Silver brazing may cause defects in certain alloys, e. One special silver brazing method is called pinbrazing or pin brazing.

It has been developed especially for connecting cables to railway track or for cathodic protection installations. The method uses a silver- and flux-containing brazing pin, which is melted in the eye of a cable lug.

The equipment is normally powered from batteries. Braze welding is the use of a bronze or brass filler rod coated with flux to join steel workpieces.

The equipment needed for braze welding is basically identical to the equipment used in brazing. Since braze welding usually requires more heat than brazing, acetylene or methylacetylene-propadiene MAP gas fuel is commonly used.

The name comes from the fact that no capillary action is used. Braze welding has many advantages over fusion welding. It allows the joining of dissimilar metals, minimization of heat distortion, and can reduce the need for extensive pre-heating.

Additionally, since the metals joined are not melted in the process, the components retain their original shape; edges and contours are not eroded or changed by the formation of a fillet.

Another effect of braze welding is the elimination of stored-up stresses that are often present in fusion welding. This is extremely important in the repair of large castings.

The disadvantages are the loss of strength when subjected to high temperatures and the inability to withstand high stresses.

Carbide, cermet and ceramic tips are plated and then joined to steel to make tipped band saws. The plating acts as a braze alloy. The "welding" of cast iron is usually a brazing operation, with a filler rod made chiefly of nickel being used although true welding with cast iron rods is also available.

Ductile cast iron pipe may be also "cadwelded," a process that connects joints by means of a small copper wire fused into the iron when previously ground down to the bare metal, parallel to the iron joints being formed as per hub pipe with neoprene gasket seals.

The purpose behind this operation is to use electricity along the copper for keeping underground pipes warm in cold climates. Vacuum brazing is a material joining technique that offers significant advantages: extremely clean, superior, flux-free braze joints of high integrity and strength.

The process can be expensive because it must be performed inside a vacuum chamber vessel. Temperature uniformity is maintained on the work piece when heating in a vacuum, greatly reducing residual stresses due to slow heating and cooling cycles.

This, in turn, can significantly improve the thermal and mechanical properties of the material, thus providing unique heat treatment capabilities.

One such capability is heat-treating or age-hardening the workpiece while performing a metal-joining process, all in a single furnace thermal cycle.

Products that are most commonly vacuum-brazed include aluminum cold plates, plate-fin heat exchangers, and flat tube heat exchangers. Vacuum brazing is often conducted in a furnace; this means that several joints can be made at once because the whole workpiece reaches the brazing temperature.

The heat is transferred using radiation, as many other methods cannot be used in a vacuum. Dip brazing is especially suited for brazing aluminium because air is excluded, thus preventing the formation of oxides.

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Get Details. We're an open book. Start by getting rid of oil and grease. In most cases you can do this either by dipping the parts into a suitable degreasing solvent, by vapor degreasing, or by alkaline or aqueous cleaning.

If the metal surfaces are coated with oxide or scale, you can remove those contaminants chemically or mechanically. For chemical removal, use an acid pickle treatment.

Make sure that the chemicals are compatible with the base metals being cleaned and that no acid traces remain in crevices or blind holes.

Mechanical removal calls for abrasive cleaning. Particularly in repair brazing, where parts may be very dirty or heavily rusted, you can speed the cleaning process by using an emery cloth, grinding wheel, or file or grit blast, followed by a rinsing operation.

Once the parts are thoroughly clean, flux and braze them as soon as possible to reduce the chance for recontamination of surfaces by factory dust or body oils deposited through handling.

Note that certain cleaning mediums will leave a residue and embed in the surface, making it unwettable. Flux is a chemical compound applied to the joint surfaces before brazing.

Its use, with a few exceptions, is essential in the atmospheric brazing process. This is because heating a metal surface accelerates oxide formation, the result of a chemical reaction between the hot metal and oxygen in the air.

If you don't prevent these oxides from forming, they'll inhibit the brazing filler metal from wetting and bonding to the surfaces. A coating of flux on the joint area shields the surfaces from the air, preventing oxide formation.

It also dissolves and absorbs any oxides that form during heating or that were not removed completely in the cleaning process.

You can apply flux in any way to the joint as long as you cover the joint surfaces completely. Flux conventionally is made in a paste, so it's usually most convenient to brush it on.

But as production quantities increase, it may be more efficient to apply the flux by dipping: dispensing a premeasured deposit of high-viscosity flux from an applicator gun.

Typically, you apply flux just before brazing if possible so it has the least amount of time to dry out and flake off or get knocked off the parts in handling.

Choose a flux that's formulated for the specific metals, temperatures, and conditions of your brazing application.

Once your parts are cleaned and fluxed, hold them in position for brazing. Be sure they remain in correct alignment during the heating and cooling cycles so that capillary action can do its job.

If the shape and weight of the parts permit, the simplest way to hold them together is by gravity. You also can aid gravity by adding extra weight as long as you don't add too much.

If you add too much weight, your clearances may not be maintained, and the brazing filler metal may be forced out of the joint area.

Also remember that adding weight to the parts increases their mass, and that will increase the time required to raise the parts to the brazing temperature.

The actual brazing involves heating the assembly to brazing temperature and flowing the filler metal through the joint.

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