brazing operation instruction

DN：VAY/M-O-05 versions ：C REV：1 Date ：2012-11-20

Revision record
version Modify date REV abstract
C0 2012-12-05 P2 Reference ：VAY4-05-02C

1.0 Purpose
 brazing operation instruction
DN：VAY/M-O-05 versions ：C REV：1 Date ：2012-11-20

This procedure is specially established as the standard for the copper brazing of

AHU and unit pipe and enclosure

2.0 Scope

This standard includes all the copper brazing process and the responsibility of
the inspector
3.0 Reference Document

Non

4.0 Definition

Non

5.0 The content of procedure

5.1 Material（brazing rod）

5.1.1 Four kinds of alloy can be used for brazing, they were chosen for use

according to the type of weld metal substrate .（refer to table 1）

melting
Ag ingredient Scaling
Body temperature colour remark
% % powder
℃

92.7Cu 705-800 Low

Cu-Cu 0 7.3P red N strength

connection

Cu-Cu& 5.0Ag Middle

copper 5 88.7Cu 645-730 strength

red N
alloy 6.3P connection

15.0Ag Good
Cu-Cu&
15 80.0Cu 645-700 liquidity
Cu-brass blue Y
5.0P and
 brazing operation instruction
DN：VAY/M-O-05 versions ：C REV：1 Date ：2012-11-20

toughness

38.0Ag Good
Brass-steel
38 36.0Cu 650-720 toughness
steel-Cu blue Y
28.0Zn and filling

Table 1
5.1.2

These alloys have been classified to provide possible good brazing results.It is very

important to choose correct alloy.otherwise, the joint will not weld together.For

example, 5% of the silver electrode and 15% of the silver electrode,If use them to

weld steel, will form a very fragile connection, no matter how good the joint is.

5.1.3 The four kinds of alloy can be identified by color.half silver electrode

should keep together with the whole one with logo， silver electrode without logo

is forbidden for use

5.2 Pretreatment and performance treatment

5.2.1 It is very important to clean the material surface before brazing，for the

dirty surface will weaken the connection. The brazing strength is based on the

contact area between the base body and the brazing rod.And we can improve the

base body surface roughness to get more contact area

5.2.2 All the brazing joint should be clean up before brazing, except for Cu-Cu

brazing. Can use sand band or abrasive cloth or stainless brush to clean up the

surface，and remove the granule in time during grinding,and replace the sand

band if dirty

5.2.3 It just need to be cleaned the same length of the pipe as we need. the too

long cleaned pipe will lead to the waste of the brazing rod，and also reduce the

pipe diameter to result in brazing gap

5.3 Brazing flux

 brazing operation instruction
DN：VAY/M-O-05 versions ：C REV：1 Date ：2012-11-20

5.3.1 Flux is helpful to brazing and is often essential.Its main purpose is as

follows

a. Prevent to form oxides on base body and filler material

b. Reduce the surface tension of brazing

c. Prevent or reduce metal oxide

d. Indicates the correct temperature of filling material

5.3.2 Keep the flux clear.and flux is needed for components connection.

5.3.3 Copper phosphorus alloys(no silver)electrode is used for Cu-Cu type,and

electrode itself has the function of flux,so there is no need to use flux.

5.3.4 After brazing, brazing slag must be removed in time to prevent corrosion.it

is a good method to remove the slag --- put the brazing area into the water before

full cooling.it is allowed to cool in air for 15 seconds before put into water.Thermal

shock will lead to crack of filler metal,So we can use Soggy rag to scrub brazing

area to remove flux.Check and clean residual flux and slag after brazing if any

5.4 Inert gas

5.4.1 Oxidation will appear on the base body with the improving of

temperature.Copper oxidation can produce bronze and steel oxidation can

produce rust. So，brazing is harmful for the copper pipe near the brazing area，

and the proper measures must be taken to prevent the oxidation and remove oxide

skin

5.4.2 Putting the brazing area into water can remove most of oxide skin，and

spraying inert gas during brazing can prevent oxidation

5.4.3 The operator should make the device of the inlet and outlet open,so as to

prevent high pressure to blow away the melting metal from brazing area

or produce micropore
 brazing operation instruction
DN：VAY/M-O-05 versions ：C REV：1 Date ：2012-11-20

5.4.4 Each operator can modify the flow according to the actual situation. Using

too much inert gas is a waste，and is harmful to people’ health

5.4.5 Before brazing,it is needed to spray inert gas for some time to seperate

components from air. Don't allow direct brazing without nitrogen treatment

5.5 Valve, assembly and visual effect -- -- -- -- -- -- -- smooth brazing

5.5.1 Components of brazing line of the above parts need different technologies

and conditions.The heat produced during brazing can make the surface of the

valve warp and burned gaskets,so the components need proper

protection---wrapped up the components with a piece of wet rag to prevent

damage

5.6 process

5.6.1 Clean surface and ensure the pipe is straight

5.6.2 After cleaning，brush the flux on the joint area smoothly

5.6.3 Insert pipe to the end of the sleeve ,then rotate the pipe gently to make

flux evenly spread on the surface of each other. Then begin brazing. Attention ,you

should begin brazing within two or three hours after assembly

5.6.4 Adjust switch,let the inert gas spray on the heated parts with uniform

velocity,so as to guarantee brazing quality and prevent changing color

5.6.5 Choose the correct brazing nozzle size and adjust the gas mixture ratio

and pressure according to the nominal diameter of the brass,so as to improve the

temperature of joint area quickly.Focus flame on the joint area ,and move it back

and forth to expand heating area. When the needed temperature is

reached,remove the flame and be careful not to overheat.

5.6.6 Test and make sure to get the right temperature.When the filter metal

begin flowing into the joint,remove the heating,and keep adding flux. If the flux
 brazing operation instruction
DN：VAY/M-O-05 versions ：C REV：1 Date ：2012-11-20

burn,the flux can not flow into the joint,and need to braze again. Overheat will

damage the joint

5.6.7 When unbroken small fillet weld filler metal appeared around the joint

area , consider full brazing.

5.6.8 Don't let brazing nozzle flame heat the filler metal directly

5.6.9 Don't add too much filler metal to the joint area

5.6.10 While joint area is still hot,remove the redundant flux with wet cloth.

5.6.11 Before brazing, removed the equipment which will be easily damaged

while brazing,in order to reduce the damage ASAP

5.6.12 All brazing type defect,except for Cu-Cu,should be removed and clean up.

If the components were not damaged by brazing, can be brazed again

5.7 Pipe brazing

5.7.1 1 1/8" pipe or larger ones are difficult to get the correct temperature for

the whole joint area at the same time.Therefore, the large size components

(including piping and joint area) need a proper preheating

5.7.2 If it is difficult to heat the whole joint area to the ideal temperature at the

same time, divide the whole joint area into several small areas，and then deal with

them seperately

5.8 Inspection and acceptance criteria

5.8.1 Clean

There is no oxide skin or flux with visual inspection. overheating will produce

oxide skin and slag that can be removed away only by hairbrush and

grinding,which can judge whether overheat

5.8.2 Appearance

The brazing area should be smooth and looks silvery yellow,there will be

shrinkage and overheat if the surface is rough.The fillet size of brazing should
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DN：VAY/M-O-05 versions ：C REV：1 Date ：2012-11-20

comply with requirement. Outflow and spots ,caused by using too much filler, are

not allowed.

5.8.3 Excess filler metal does not combine with parent metal into alloy, so it will

not increase the strength.

5.9 The brazing guidance

5.9.1 Pay attention to choose the correct flux, heating temperature and the

correct using of flux

5.9.2 When brazing, joint must be in good condition

5.9.3 The function of Capillary

Filler metal flow into the joint smoothly, which shows the correct temperature

5.9.4 Opportunity

It is very important to know when to add flux, when to heated, when to

braze.To apply flux after cleaning immediately and begin brazing

5.9.5 Treatment after brazing

Remove the slag after brazing

 VAY/M-O-05
BPS–001
VIKING AIRTECH (YANTAI) CO.,LTD
PAGE 1

BPS No. BPS -001 Date 2012-11-20

Welding process Torch Brazing Types manual
Flow Position Horizontal and Vertical up or down

JOINTS DESIGN ：
Joint Design Lap Joint

Joint Clearance 0.05mm~0.3mm

Length of Overlap 10mm Min
Method of Applying Filler metal Face Feeding

Base metal：
P No. TP2， （C12000）
Base Metal Specification （ASTM B280）
GB/T17791-2007，
Base Metal Thickness 0.75mm to 3.5mm

Pipe size ALL

BRAZING FILLER METAL

Filler Metal Specification: GB/T6418-2008，（AWS A5.8） classification: BCu80PAg，（BCuP-5）
Filler Metal Trade Name: Yu Guang
Filler Rod Size 2.0mm or 2.4mm Filler Metal Product Form silver alloy welding wire

BRAZING TEMPERATURE
Brazing Temperature Range 645℃ to 730℃

BRAZING FLUX，FUEL GAS

Flux NA
Fuel Gas Oxy-acetylene
Gas Purging (Option) 100% N2

FLOW POSITION POST BRAZE HEAT TREATMENT

Position Horizontal and Vertical up or down Temper NA Time NA
 VAY/M-O-05
BPS–001
VIKING AIRTECH (YANTAI) CO.,LTD
PAGE 2
TECHNIQUE
Cleaning Prior to Brazing Power brush or Sand paper or Reaming
The right heating control ：

Post braze Cleaning fine file，steel wool or emery cloth

Nature of Flame Neutral

1. Clean the joints mechanically using a fine file，steel wool or emery cloth until bright metal is exposed.
2. Joint clearance should be within 0.05mm to 0.3mm.
3. Heat to the correct temperature and evenly both the pieces to be silver brazed.
4. For brazing，a soft neutral flame or a slight feather (reducing flame) on the inner cone is used.
5. Allow the location of the brazing in water remove slag after cooling 15 seconds.

Prepared By:
Check By: Approved By:

Date Date Date

2012-11-20 2012-11-20 2012-11-20