Thermal Joining

Module IV. Lesson 3

 Thermal Joining

Thermal joining refers to the process of joining

two or more materials using heat. This can include
techniques like welding, soldering, brazing, and
adhesive bonding where heat is applied to create a
bond between the materials.
 Purpose of thermal joining

Thermal joining, which includes methods like welding,

brazing, and soldering, serves the primary purpose of
securely and permanently joining two or more materials
usually metals through the application of heat. This heat
causes the materials to melt and fuse together, creating a
strong bond upon cooling.
 Types of thermal joining

• Welding

• Brazing

• Soldering
 WELDING
Welding is one of the most common
methods of thermal joining, where two or
more parts are fused together by melting
the workpieces and often adding a filler
material.
 Processes of Welding

➢ FUSION WELDING
Heat is applied to melt the base metals. In many fusion welding
processes, a filler metal is added to the molten pool during welding to
facilitate the process and provide strength to the welded joint.

➢ Solid State Welding

In this method joining is done by coalescence resulting from
application of pressure only or a combination of heat and pressure.
Even if heat is used, the temperature in the process is less than
the melting point of the metals being welded.
Types of Fusion Welding
1. Arc Welding
Arc welding is a type of welding
process using an electric arc to create
heat to melt and join metals. A
power supply creates an electric
arc between a consumable or non-
consumable electrode and the base
material using either direct DC) or
alternating (AC) currents.
Types of Fusion Welding
2. Resistance Welding
In this operation, electric resistance
is generated to flow of current that
generates heat energy between two
contacting surfaces that are held in
pressure.
Types of Fusion Welding
3. Laser Welding
Employs a high-intensity laser to melt
the metal in small, precise areas. It's
useful for high-speed, automated
environments.
 Types of Solid-State Welding
1. Diffusion welding
Two-part surfaces are held
together under pressure at elevated
temperature and the parts join by
solid state diffusion.
 Types of Solid-State Welding
Friction welding
Joining occurs by heat of
friction and plastic
deformation between two
surfaces.
Tools/Equipment/Materials of Welding

• Welding Power Supply –Provides the electrical

energy necessary to create arcs for arc welding
processes such as TIG (Tungsten Inert Gas), MIG
(Metal Inert Gas), and stick welding.

• Welding Electrodes - Consumable (for MIG and

stick welding) or non-consumable (for TIG
welding) rods that facilitate the welding process
by producing the weld when melted.
Tools/Equipment/Materials of Welding

• Welding Torch or Gun - Used to direct the arc

and filler material to the weld area.
• Filler Materials - Additional metals added to
the weld to help fill the joint (available as rods
or wire).
• Protective Gear - Includes welding helmets,
gloves, and protective clothing to shield the
welder from sparks, intense light, and heat.
 Types of Brazing

• Torch Brazing: Uses a gas-fueled flame to heat

the metal pieces and the filler.
• Furnace Brazing: Involves the use of a furnace
to provide the necessary heat, allowing
multiple joints to be brazed simultaneously.
• Induction Brazing: Uses electromagnetic
induction to heat the metal parts and the filler
metal.
 BRAZING

Brazing involves joining two or more

metals by melting and flowing a filler
metal into the joint, the filler metal having
a lower melting point than the adjoining
metal.
Types of Brazing

Torch brazing Induction Brazing

In this method, the heat High frequency induction
required to melt and flow filler heating for brazing is clean and
metal is supplied by a fuel gas rapid, giving close control of
flame. The fuel gas can be temperature and location of
acetylene, hydrogen, or propane heat. Heat is created by rapidly
and is combined with oxygen or alternating current which is
air to form a flame. This process induced into the workpiece by
is readily automated and an adjacent coil.
requires low capital investment.
Torch brazing requires the use of
a flux, so a post- braze clean is
often required.
Types of Brazing
Resistance Brazing Furnace Brazing Dip Brazing
This is a process in Furnace brazing is This involves
which heat is a semi-automatic immersion of the
generated from process that is widely entire assembly into
resistance to an used in industrial brazing bath of molten braze
electrical current (as operations due to its alloy or molten flux.
for induction brazing) flexibility to mass In both cases the bath
flowing in a circuit production and the use temperature is below
of unskilled labor. One of the solidification
which includes the
the main advantages of point of the parent
work pieces, The furnace brazing is the metal, but above the
process is the most ease with which it can melting point of the
applicate to relatively produce a large number filler metal.
simple joints in metals of small parts that are
which have high easily toothed or self-
electrical conductivity. detecting.
Filler Metal

The metal to be added in making a

welded, brazed or soldered joint. The
filler metal flows into the gap between
close-fitting parts by capillary action (the
force by which liquid, in contact with a solid,
is distributed between closely fitted facing
surfaces of the joint to be brazed).
 Flux

Material used to prevent, dissolve or facilitate

removal of oxides and other undesirable surface
substance. A flux such as borax is required to
prevent oxides from forming while the metal is
heated.
 SOLDERING
Soldering is similar to brazing
but generally uses fillers that
melt at below 450°C. It’s
commonly used for electrical
circuit connections.
 Types of Soldering

Torch Soldering Furnace Soldering

Torch soldering (TS) Furnace soldering (FS)
utilizes a fuel gas flame as the encompasses a group of
heat source in the soldering reflow soldering
process. The fuel gas is mixed
with either air or oxygen to techniques in which the
produce the flame, which is parts to be joined and
applied to the materials to be preplaced filler metal are
soldered until the assembly put in a furnace and then
reaches the proper soldering heated to the soldering
temperature. temperature.
 Types of Soldering

Induction Soldering
Resistance soldering
Induction soldering uses
a precise electromagnetic Resistance Soldering is the
field to heat two or more name applied to a technique
electrically conductive where the heat to melt solder
materials in order to join is instantaneously generated
them with a filler material by passing through a high
that melts at a temperature amperage electrical current
below the melting point of through a resistive material.
the joined materials.
 Types of Soldering

Dip Soldering
Dip soldering is a small-scale
soldering process by which
electronic components are
soldered to a printed circuit
board (PCB) to form an electronic
assembly. The solder wets to the
exposed metallic areas of the
board (those not protected with
solder mask), creating a reliable
mechanical and electrical
connection.
Tools/Equipment/Materials in Soldering

• Soldering Copper - Sometimes called a soldering iron, is

a traditional tool for this work. For greater efficiency
two coppers are generally used when soldering; one is
heated while the other is being used. For this reason,
they are sold in pairs.
• Gas furnace - Is frequently used to heat coppers.
• Desoldering Tools - Such as desoldering pumps or solder
wicks, used for removing solder for corrections or
disassembly.
Tools/Equipment/Materials in Soldering

• Soldering Iron or Gun - Tool that heats the solder to

its melting point.
• Solder - A metal alloy with a low melting point used to
join pieces together without melting them.
• Flux - Used to clean and prepare the surfaces for
soldering, often included in the core of solder wires.
• Soldering Station - Provides a holder for the soldering
iron, sponge for cleaning the tip, and sometimes
variable temperature controls.
 THE END
THANK YOU