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Brazing: An Important Joining and Fastening Option Presented By: Marcin Kuta & Creed Darling

Presentation Content
Introduction to Metal Joining Types Differences Between Welding and Brazing The Six Brazing Fundamentals Brazing Products Brazing in Todays Industries Questions

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History of Lucas-Milhaupt
Handy & Harman was founded in 1867 Lucas-Milhaupt founded in 1942 One of the largest North American suppliers of brazing and soldering alloys Offering full line of brazing and soldering consumables including wire, strip, paste, powder, fluxes, and engineered forms

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Common Types of Metal Joining

Welding Joining of metal substrates by applying heat to produce a joint through fusion across the substrate interfaces TIG, MIG, Laser, Electron Beam, etc. Structural Adhesives Substances that hold metals together by surface attachment Reactive, Chemically Reactive, Non - Reactive

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Common Types of Metal Joining Continued

Mechanical Fastening
Secures base metals firmly by mechanical means Tension, Compression, Shear Fasteners, etc.

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Brazing
Joins similar and dissimilar materials by heating them to a temperature above 840 F but below the solidus of the base materials. Molten filler metal is distributed between the closely fitted base materials by capillary attraction. Torch, Induction, Furnace, Resistance, etc.

Welding Types
TIG (Gas Tungsten Arc Welding)

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Heat is produced by the electric arc between the W-electrode and base metals to produce joint. Inert shielding gas flows around the arc to keep joint area clean. Only base metal melts, additional filler metal is added if needed.

MIG (Gas Metal Arc Welding)

Base metal and continuously fed electrode are melted by an electric arc created between the two. Inert shielding gas flows around the arc to shield weld area.

Welding Types Continued

Resistance Spot Welding

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An electrical current is passed through the assembly by two electrodes and pressure is applied causing a spot weld between the electrodes

Electron Beam Welding

A focused stream of electrons heats and fuses the base materials together

Laser Beam Welding

A single frequency light beam causes the assembly to heat up to its melt temperature and fuse together

Advantages/Disadvantages: Welding
Advantages of Welding
Most common method of joining metals Produces very high joint strengths Leak tight joints

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Disadvantages of Welding
Difficult to join dissimilar materials High base material heat distortion More difficult to automate Requires skilled operators

Structural Adhesive Types

Reactive
Adhesive is set/solidified by a chemical reaction Common types: Epoxies, Anaerobics, Cyanoacrylates, Polyurethanes, etc.

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Hot Melt
Applied as heated liquid, sets as it cools Thermoplastic Resins

Non-Reactive
Chemical reaction does not set adhesive Common Types: Silicones, Plastisols, etc.

Advantages/Disadvantages: Adhesives
Advantages

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Very versatile and economic method of joining that produces leak tight joints of metals and non-metallics Expansive variety of adhesive choices allows for multiple application use

Disadvantage
Relatively low strength compared to brazing and welding (2,000-10,000 PSI Tensile) Many adhesives require extensive cure times Soften at elevated temperatures The majority of adhesives will not withstand operating temperatures above 500F

Mechanical Fastening Types

Tension Fasteners
Most frequently used. Elongate under load. Common types: Pan Heads, Hex Heads, Truss Heads, etc.

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Compression Fasteners
Compress under load Common types: Set Screws, Washers, etc.

Shear Fasteners
Carry load perpendicular to fastener axis Common types: Dowel Pins, Roll Pins, etc.

Advantages/Disadvantages: Mechanical Fasteners

Advantages
Provide a versatile method of joining similar and dissimilar materials Many fasteners are reusable High strengths Low operator skill required

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Disadvantages
Do not distribute stress well. Can create stress concentration sites. Does not produce hermetic joints High material cost Can significantly increase weight and size of assembly

Brazing Types
Torch
Most versatile form of heating. Fast heating cycles. Low to high production volumes.

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Induction
Very fast, localized heating. Medium to high production volumes.

Resistance
Fast, localized heating. Medium to high production

Furnace
Broad, uniform heating. Batch to high production.

Advantages/Disadvantages: Brazing
Advantages

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Versatile method that provides economic and hermetic joints on metallics and non-metallics Disassembly High strengths

Disadvantages
Variable consumable cost Higher process temperature than mechanical fasteners and adhesives

Comparison of Joining Methods

Brazing Strength of Joint Temperature Resistance Leak Tightness Versatility of Joint Design Cost Effeciency Operator Skill Required Safety Concerns Ability to Automate Distribution of Stress Aesthetics Ease of disassembly
+ + + + + + +

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Welding
+ + + + -

Adhesives
+ + + -

Mechanical Fastening
+ + +

+ High

Medium - Low

Brazing vs. Welding

Strength

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Brazing: Equal to or greater than the strength of the weakest base material Welding: Equal to or greater than the strength of the base materials

Aesthetics
Brazing: Smooth fillets Welding: Rough weld bead

Brazing vs. Welding Continued

Operator Skill Required

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Brazing: Limited training is required for torch brazing Welding: Highly trained, certified operators are required for TIG, MIG, and other welding processes

Automation
Brazing: Torch, induction, furnace, and resistance brazing are easily automated to allow for high production quantities Welding: Automation is limited with the majority of welding processes

Case Studies: Why Brazing?

Krueger International Green Bay, WI Application
Metal frame chairs and furniture. Typically steel to steel joints where the seat base meets the legs.

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Why Braze?
Brazing is the only choice when strength and aesthetics are the primary concern. Brazing provides a strong and durable joint while also producing smooth and clean joints.

Solution
Brazing at a indexing brazing machine with Braze 505 (BAg-24) rings or slugs.

Case Studies: Why Brazing?

Thermal Transfer - Racine, WI Application
Joining of Cu tubes to a steel manifold for heavy duty cooling applications. The various sizes of tubes and the number of tube rows for each heat exchanger Thermal Transfer produces requires a versatile joining method. The joining method must be a fast process that produces a leak tight joint.

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Why Braze?
Brazing is ideally suited to join dissimilar materials like Cu to steel where welding is not.

Solution
Induction brazing with Handy One Flux Cored Braze 560 (BAg-7) rings.

What is Brazing?
American Welding Society Definition

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Brazing: A group of welding processes which produces coalescence of materials by heating them to a suitable temperature and by using a filler metal having a liquidus above 840 F (450 C) and below the solidus of the base materials. The filler metal is distributed between the closely fitted surfaces of the joint by capillary attraction.

Definition of Brazing Terms

SOLIDUS (MELT POINT) - The highest temperature at which filler metal is completely solid. LIQUIDUS (FLOW POINT) - The lowest temperature at which a filler metal is completely liquid. EUTECTIC COMPOSITION - A specific filler metal composition that melts and changes completely from a solid to a liquid, at one temperature.

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Silver-Copper Phase Diagram

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Definition of Brazing Terms

CAPILLARY ACTION - The force that pulls a liquid through two parallel surfaces. Capillary stops at .012/. 015 gap. WETTING - The ability of filler metal to plate out on the surface of a material FLUX - A material used to prevent, dissolve or facilitate removal of oxides from metal surfaces during heating OXIDE - A substance resulting from the combination of a metal and oxygen. Its presence on a metal surface usually causes the surface to be totally non-wettable by a brazing filler metal.

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Schematic of a Braze Joint

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Filler Metals

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The Six Fundamentals of Brazing

1. 2. 3. 4. 5. 6. Good Fit and Proper Clearance Clean Metals Proper Flux/Atmosphere Proper Fixturing Proper Heating Final Cleaning

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1. Good Fit and Proper Clearance

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Braze alloy relies on capillary action to draw alloy through joint interface Braze joint gap dependent upon filler metal type and flux/atmosphere used Clearance should be determined at brazing temperature

1. Good Fit and Proper

Clearance
Gap affects capillary action and strength
Too large - no strength Too small - no capillary action Maximum gap is 0.012

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2. Clean Metal
Need metal to metal surface Contaminants will affect braze quality
First degrease then chemical or mechanical cleaning Types of Contaminants:
Cutting fluids from machining Grease, oil and wax Dirt /Dust Scale from furnace heat Oxide from air Dirty hands

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Degrease or wash Degrease Wash Chemical or mechanical Chemical or mechanical Wash

3. Proper Flux/Atmosphere
Four Functions of Flux
1. 2. Clean residual oxide Protect base metal and filler metal from oxygen during heating 3. Assists filler metal to flow - reduces surface tension 4. Temperature indicator

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3. Proper Flux/Atmosphere: Flux as a Temperature Indicator

1. 212 F Water boils off 2. 600 F Flux becomes white and puffy 3. 800 F Flux wets surface but has milky appearance 4. 1100 F Flux completely liquid and clear like water 1

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3. Proper Flux/Atmosphere
Flux is not meant to clean dirty parts
Dissolve residual oxide & protect from oxygen

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Shouldnt heat flux too fast

Flux will spatter off assembly

Normally applied by brushing, dipping or blotting

3. Proper Flux/Atmosphere: Atmospheres

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Atmosphere depends on the base material(s) and brazing alloy used Types of Atmospheres:
Vacuum Pure Hydrogen Cracked Ammonia Inert Gas Nitrogen, Argon, etc

3. Proper Flux/Atmosphere: Atmospheres

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Source: Welding Journal/Welding Research Supplement, May 1970

4. Proper Fixturing
Methods of Fixturing Self Fixturing
Best method most versatile Typically used in high automation furnace applications

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External Fixturing
Typically used in low quantity or complex assemblies

4. Proper Fixturing: Self Fixturing Methods

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Source: AWS Brazing Handbook

4. Proper Fixturing: External Fixturing Methods

Must hold alignment of part
Keep weight down thin yet ridged Keep open to allow heat in

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Must allow expansion of base metal If pressure must be applied use:

Moveable weights Weighted levers Cams Stainless or Inconel springs

5.

Proper Heating: Main Methods

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Torch Induction Resistance Furnace

5. Main Heating Methods: Torch

Heat is generated by fuel/gas flame The most versatile form of heat Economical for large or small quantities Equipment is generally inexpensive Braze alloy can be pre-placed or face fed Lends itself to automation Flux typically required

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5. Main Heating Methods: Induction

H=I2R H= heat produced I= Induced current R= Electrical resistance of the material Localized heating prevents base metal distortion Rapid heating may prevent liquation Repeatable process not requiring the use of trained operators

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5. Main Heating Methods: Resistance

Heat is produced by base material(s) resistance to the electrical current being passed through itself Rapid heat cycles Minimal base metal distortion Flux typically required

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5. Main Heating Methods: Furnace

Electrically heated or Oxy/Fuel fired Various types of atmospheres Very efficient and economical in mass production Accurate temperature control Uniform heating Multiple braze joints completed in one operation Can eliminate fluxing and post braze cleaning

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6. Final Cleaning
Flux removal
Corrosion Contamination - Especially internally to eliminate possible damage to a system Inspectability Appearance

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Clean surface for post-braze processes

6. Final Cleaning: Quenching Considerations

Do not cool too quickly (allow filler metal to solidify)
Results in cracking Rough looking joints May change physical properties of base metal

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Do not quench materials with a large difference in C.O.E.

Brazing Consumables
Standard Brazing Alloy Forms
Wire Forms Strip Forms

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Active Metal Brazing Alloys Flux Cored Alloys Paste/Powder Flux

Brazing Consumables: Wire Forms

Solid Wire
Sizes: 0.010 0.125

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Preforms/Rings:
Inside Diameter: 0.040 12.0 Wire Diameter: 0.008 0.125

Brazing Consumables: Strip Forms

Bulk Strip
Typical Sizes: Width: 0.062- 6.00 Thickness: 0.001- 0.125

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Preforms
Washers Discs Engineered Forms and Shapes

Brazing Consumables: Active Metal Alloys

Active Metal Paste
Powder alloy, active metal, and binder in one compound

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Active Metal Strip and Wire

True alloy Ti coated strip

Tiger Ink
Active metal paint

Brazing Consumables: Flux

Paste Flux
Low Temperature Flux White, Black High Temperature Flux White, Black

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Powder Flux Liquid Flux Dispensable Flux Gas Flux

Brazing Consumables: Paste

Low Temperature Air Atmosphere Brazing Paste
Flux, Binder, Brazing Alloy

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Furnace Brazing Paste

Fluxless Binder, Brazing Alloy

Standard Mesh Sizes

-100, -140, -200, -325

Brazing Consumables: Flux Cored

Simplifies the Brazing Process No separate flux to buy or to apply onto parts Produces Stronger, Better Quality Joints Consistent application of flux & alloy Enhanced process control & higher productivity Reduces flux inclusions (gaps) Reduces Flux Exposure Reduces Post Braze Cleaning Costs

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Brazing in Todays Industries

Automotive Industry
Fuel Rails Heat Exchangers Air Lines Etc.

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Common Alloys Used

AWS: BCu, BAg, BCup, BNi, etc.

Brazing in Todays Industries

Electrical Industry Vacuum interrupters Sensors Electrical contacts Optical electronics and lighting Etc. Common Alloys Used High Purity Alloys AWS: BAg, BAu, BNi, etc.

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Brazing in Todays Industries

Heating and Refrigeration
Compressors Refrigeration Lines Ice Cube Trays Etc.

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Common Alloys Used

Low temperature alloys AWS: BCuP, BAg, etc.

Brazing in Todays Industries

Aerospace
Turbine Engines Impellers, Stator/Vane, etc Fuel Systems Sensors Etc.

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Common Alloys Used

High Purity Alloys BAu, BNi, BAg, etc.

Brazing in Todays Industries

Plumbing Mining and Cutting Tools Medical and Dental Food Industry Military Construction

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Summary/Conclusion
Brazing provides a very versatile method of joining similar and dissimilar metallics and non-metallics This process is used by numerous industries and provides strong, leak tight joints for a variety of applications Brazing is suitable for use for quantities ranging from batch to high production

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