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
brazing operation instruction
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
