02230271

MPT 202

Assignment 2

BE Mechanical

College of Science and Technology

Introduction.

Brazing is a metal-joining process in which two or more base metals are joined and a melted
filler metal flows into the joint. The brazing process is carried out at a temperature typically
exceeding 450°C (842°F) but lower than the melting points of the base metals. Unlike welding,
where the base metals are melted, brazing has a capillary action that distributes molten filler
metal into the closely fitted surfaces of the parts being joined. Brazing is a versatile method used
for joining dissimilar metals and even non-metallic materials producing high-strength
connections with excellent thermal and electrical conductivity. The process offers several
advantages, including the ability to create precise and clean joints with minimal thermal
distortion or damage to delicate components. Brazing is widely used in various industries,
including automotive, aerospace, electronics, and HVAC due to its efficiency, cost-effectiveness,
and reliability in producing high-quality joints.

Working Principle.

One of the most crucial steps in the metal joining process is the cleaning of the base metal
surfaces. Emery cloth or wire brush are both great tools to remove contaminants.

Having calculated joint gaps for the liquid filler metal to achieve surface tension with the
workpiece, the brazing operation begins with properly positioning the assembly. A torch is
normally used to slowly heat the workpiece’s metal surface and filler metal into its brazing
temperature.

As the filler metal liquefies, capillary action lets it pass through the tight spaces, thus forming a
bond between the surface of the base metals.

The brazed joints are formed as it cools down with the assembly (workpiece).
Brazing Characteristics.

1. The melting point of the filler metal is substantially lower than that of the base metal by at
least 50°C (90°F). This ensures that the base metal remains in a solid state during the brazing
process.

2. The composition of the filler metal is different from that of the base metal. This difference is
made to achieve specific metallurgical properties and compatibility with the base metal.

3. The molten filler metal is drawn into the joint gap between the base metal components through
wetting action and capillary force. This phenomenon is governed by factors such as surface
tension, viscosity, and gap clearance, typically ranging from 0.025 to 0.125 mm for optimal
results.

4. The metallic bond is established through the diffusion of atoms at the interface between the
liquid filler metal and the solid base metal. This diffusion process creates an intermetallic layer,
which is crucial for the formation of a strong, continuous metallurgical bond.

Types of Brazing Process.

1. Torch Brazing:

Torch brazing is the most common method of mechanized brazing. It is commonly used for
smaller-scale production. A heated gas torch is set to the required composition to heat the
workpiece. A mixture of acetylene, propane, etc. is burned with air or oxygen for the flame.

There are three main types of torch brazing:

◦ Manual torch brazing. ◦ Machine torch brazing. ◦ Automatic torch brazing.

2. Induction Brazing:

The heat required for the brazing metals is obtained from a high-frequency alternating current
(AC) consisting of a motor generator, resonant spark gap, and vacuum tube oscillator. This
process is fast and the current is induced without any contact with the parts.

3. Resistance Brazing:

An electric current is passed through the electrodes to the workpiece where heat is generated due
to resistance. The filler metal is applied once the joint is hot enough. The parts comprising the
joint constitute a part of the electric circuit.

4. Vacuum Brazing:

The workpiece is heated in a vacuum chamber where oxygen is removed to prevent oxidation.
This gives vital benefits such as extremely clean, superior, flux-free brake joints of high integrity
and strength. This process is expensive as it is done inside a vacuum chamber vessel.
Procedure:

1. Preparation of Base Metals:

◦ Cleaning: Remove any oxidation, grease, or debris from the surface of the workpiece. This can
be done using chemical cleansers, abrasives, or mechanical techniques like wire brushing.

◦ Fitting: To enable the capillary action to draw the molten filler metal into the joint, ensure the
components fit together with a little gap (usually between 0.03 and 0.08 mm).

2. Selection of Filler Metal and Flux:

◦ Filler Metal Selection: Select a suitable filler metal with a lower melting point than the base
metals. The melting point of the filler metal should be higher than 450°C but lower than that of
the base metals.

◦ Application of Flux: To stop oxidation during heating, flux is applied to the joint area. It
facilitates the smooth flow of filler metal and aids in surface cleaning.

3. Heating:

◦ Heat Application: The workpiece is heated, typically using an induction heater, furnace, or
torch. To prevent thermal deformation, the heat should be applied consistently.

◦ Temperature Control: To prevent overheating of the base metals, the temperature must be
controlled. Raising the temperature sufficiently to melt the filler metal and not the base metal is
important.

4. Brazing:

◦ Filler Metal Flow: The filler metal is melted and drawn into the metal joint by capillary action
after the workpiece reaches to a proper temperature. A strong bond is formed as the molten filler
metal moves between the closely fitting surfaces.

◦ Completion: Turn off the heat source and let the workpiece cool after the filler metal has passed
through the joint.
5. Post-Brazing Cleaning

◦ Flux Removal: Residual flux should be eliminated after cooling as it can be corrosive. Either
water or a chemical solution is used for this depending on the flux type.

◦ Inspection: Check for gaps, fractures, or other flaws in the joint. For crucial applications, this
can be accomplished by using methods like dye penetrant tests or X-rays.

Benefits of brazing.

◦ Creates a strong joint. The joint is as strong or stronger than the metals that are being joined.

◦ Lower temperatures are used ranging from 1150ºF (620ºC) to 1600ºF (870ºC).

◦ The base metals are never melted and generally retain their original properties.

◦ It is easier to join dissimilar metals.

◦ A brazed joint is smoother so it is more attractive.

◦ It is easier to learn and understand.

◦ It can be a fully automated procedure consuming less time and money.

Drawbacks of brazing.

◦ For some metals, brazing may produce low-strength joints.

◦ The color of the joint is often different from the base metals that are used which may not be
aesthetically pleasing.

◦ Materials to be joined must be very close together for capillary action of the molten filler
material to occur which is hard to achieve.

◦ The process can only be used for smaller pieces of metal and won’t work for large pieces since
they have to be very close together for capillary action.
Application of Brazing.

Brazing is used across many industries including:

◦ Aerospace: To fabricate and assemble jet engines and turbine blades, heat exchangers, and
airframe structures.

◦ Automobile: To manufacture and repair vehicle air conditioning systems, radiator coils, and
fuel distribution systems.

◦ Construction: This includes almost everything, ranging from tools for cutting concrete and
stone to carbide machine parts.

◦ Electrical and Electronics: To manufacture electronic components such as connectors, circuits,

and heat sinks.

◦ HVAC: In the assembly of copper piping and fittings in HVAC systems.

Safety Protocols.
1. Wear Proper Personal Protective Equipment (PPE):
◦ This includes safety goggles or face shields to protect your eyes from sparks, gloves to protect
your hands from hot materials, flame-resistant clothing, and proper footwear. The intense heat
and bright light produced during brazing can damage eyes and skin.

2. Ensure Proper Ventilation:

◦ Brazing produces fumes that can be hazardous when inhaled, especially from fluxes or metals
with coatings. Proper ventilation, such as using exhaust fans or working in well-ventilated areas,
helps reduce the risk of inhaling harmful gases.

3. Handle Gas Cylinders Safely:

◦ When using gas torches for brazing, always store and handle gas cylinders upright, secure them
properly, and check for leaks before use. Improper handling could result in gas leaks or
explosions.
4. Fire Safety Measures:

◦ Have a fire extinguisher readily available, and ensure the work area is clear of flammable
materials. Brazing involves an open flame, so having fire suppression tools nearby is essential to
prevent fires.

5. Check Equipment for Damage:

◦ Inspect hoses, torches, regulators, and other equipment for wear or damage before each use as
faulty equipment can lead to gas leaks, fire hazards, or inefficient brazing performance.

6. Proper Handling of Hot Materials:

◦ After brazing, materials remain extremely hot. Use tongs or pliers to handle these items to
avoid burns, and allow enough cooling time before touching with bare hands.

Method to improve efficiency.

1. Optimize Joint Design:

◦ Design brazed joints with the correct clearance (usually between 0.05 mm to 0.2 mm) to
promote optimal capillary action.

◦ Simplify joint geometry wherever possible to minimize the amount of filler metal required and
reduce the complexity of the brazing operation.

2. Use the Right Filler Material:

◦ Choose a filler metal that melts at a lower temperature than the base metals to reduce the heat
input required, conserving energy and reducing risk.

◦ Ensure that the filler metal composition matches the base metals to optimize bonding and
minimize the need for excessive filler material.
3. Preheat Workpieces:

◦ For large or thick workpieces, preheat the components to reduce the amount of heat energy
required during the brazing process to reduce the total brazing time.

◦ Ensure that workpieces are uniformly preheated to avoid localized overheating, which can lead
to excessive filler metal use or joint failures.

4. Automate the Brazing Process:

◦ Use robotic or automated brazing systems to improve precision and consistency, especially for
high-volume production

◦ Implement induction brazing, furnace brazing, or resistance brazing systems that allow precise
control of the heating process, improving efficiency.

5. Reduce Waste and Rework:

◦ Clean and prepare base metals thoroughly before brazing to remove oxides, grease, or
contaminants that could affect joint integrity to reduce the chances of rework due to poor
adhesion or weak joints.

◦ Implement non-destructive testing techniques.

Conclusion.

In conclusion, brazing is an invaluable technique in metal joining having particular applications,

strengths, and limitations. Though being well-informed about the processes is fundamental, but
understanding the inherent hazards such as toxic fumes, burns, and electrical shocks is even more
critical. Thus ensuring safety precautions, including using PPE, proper ventilation, and adhering
to safety protocols, is imperative to safeguard the operators, learners, and the workspace. Having
a safe and knowledgeable approach to brazing is a must for all to achieve successful and
responsible craftsmanship.
 References

admin. (2021, July 9). Types of Brazing: Definition, Principle, Applications, Advantages &
Disadvantages. Engineering Learner. https://engineeringlearner.com/types-of-brazing-
definition-principle-applications-advantages-disadvantages/

Brazing 101: Everything You Need to Know for Beginners | MachineMFG. (2024, August 16).
https://www.machinemfg.com/brazing/

Brazing Explained—Definition, Process, Types. (2022, September 13). Fractory. http://https

%253A%252F%252Ffractory.com%252Fbrazing-explained%252F

Coey. (2024, July 26). Improving Brazing Performance: Techniques and Methodologies. Eureka
Blog. https://eureka.patsnap.com/blog/improve-brazing-performance/

M, S. (2020, January 28). Types of Brazing Process: Definition, Advantages and Uses. The
Engineers Post. https://www.theengineerspost.com/types-of-brazing/

Mathew, J. (2023, June 22). Soldering Vs Brazing | Hazards and Safety Precautions.
https://www.hseblog.com/brazing-and-soldering-safe-work-practices-and-precautions/

Supply, V. L. W. (2022, September 14). Brazing: Common Applications, Benefits, and

Drawbacks. Vern Lewis Welding Supply, Inc. https://vernlewis.com/brazing/