Soldering and brazing

Advanced College of Engineering and

Management
Group members
Aashutosh Singh

ACE081BCT07

Nandani Jaiswal

ACE081BCT043

Bikash Kumar Bhusal

ACE081BCT025

Joshan Dhakal

ACE081BCT034

Anush Tirpathee

ACE081BCT016

Introduction
●​ Soldering and brazing can be used to join metals that are difficult to weld together. Some
metals or alloys that can be joined using this process are copper, brass, aluminum,
stainless steel etc.
●​ They do not require high temperatures or pressures, which reduces the risk of distortion,
warping, or damage to the base metals.
Brazing process

Brazing
Similar to soldering, except that the filler metal, called
braze, has a higher melting point above 450°C and below
the melting point of the base metals.

Also relies on capillary action to fill the gap between the

base metals with the molten braze, forming a strong joint
when it cools down.

Can be used for joining dissimilar metals, such as steel

and copper, or metals that have high melting points, such
as tungsten and molybdenum.

Brazing equipment and materials

●​ Heat source~ flame torch~ induction~ furnaces
●​ Braze (filler metal)

~copper

~silver ~aluminum ~nickel ~and their alloys…

Surface cleaning and preparation for

Brazing
●​ Remove oil and grease: Use a commercial solvent, degreasing solvent, or alkaline
solution to remove oil and grease.
●​ Remove oxides: Use an abrasive like emery cloth to remove oxides.
●​ Remove small particles: Wipe away any small particles, like emery dust, with a clean,
dry cloth.
●​ Smooth the surface: Polish the clean surface furthermore ensures perfect capillary
action and ensure strength of the joint.

Steps in the Brazing Process

●​ 1 Heating
●​ The metals to be joined are heated using a torch, furnace, or another heat source

2. Filler Metal Application

●​ A filler metal (like a rod or wire) is melted into the gap between the two pieces
3. Flux Application
●​ Flux is a special paste or powder added before heating.
4. Cleaning After Brazing:
- After the process is done, leftover flux and other residues are cleaned off.
Joint Design and Support Parts
1.​ Joint Design:

The parts to be joined should fit tightly.

A small gap (usually less than 0.1 mm) is left for the filler
metal to flow
2. Support Parts:
- While brazing, the parts need to stay in position. - Clamps, fixtures, or weights are used to hold
the pieces steady.
Why Use Brazing?
●​ Brazing makes strong and neat joints without melting the main metals. It is used in
making tools, pipes, and even in refrigerators!

Soldering
●​ Soldering is a joining process used to join different types of metals together by melting
solder.
●​ Solder is a metal alloy which is melted using a hot iron.
●​ This solder has low melting point than the work piece.

Flux
●​ Flux is a chemical compound used in soldering to prepare metal surfaces for soldering.

It has several purposes:

●​ It helps to clean the metal surfaces.
●​ It improves electrical contact between the metal surfaces.
●​ Flux removes oxide from the metal surfaces.

Soft Solder
●​ Soft solder is a material used for joining metal parts.
●​ It is usually made from tin-lead or tin-silver mixtures.
●​ It melts at a low temperature, so good for working with sensitive metal parts and
electronics.
●​ It comes in forms like wire, paste, tape, bar, or stick.
●​ When heated, it melts and flows over the metals to join them.
●​ It cools and hardens to create a strong connection.
Types of flux
●​ Rosin Based Flux

Rosin-based flux is used in electronics because it doesn't harm sensitive parts and cleans well
without being corrosive or conductive.

●​ Acid flux

Acid flux is used in plumbing because it is stronger, removes tough oxidation, and helps solder
stick better in plumbing conditions.

Importance of Flux

- Flux is essential in soldering as it removes oxides, promotes even spreading of solder, and
lowers surface tension to improve flow. It also prevents re-oxidation and impurities, ensuring
stronger, more reliable solder joints.
Soldering Process
●​ Prepare the Surface: Clean the metal parts to remove dirt and oxidation.
●​ Apply Flux: Use a brush or applicator to coat the surfaces with flux.
●​ Heat the Joint: Use a soldering iron to heat the parts evenly.
●​ Apply Solder: Touch the solder wire to the joint, allowing it to melt and flow.
●​ Cool and Inspect: Let the joint cool naturally and check for a solid connection.

Applications
Soldering and brazing are widely used in industries for creating strong,
reliable and leak-proof joints in various applications. Some of them are
listed below:

Applications of Soldering in industries

1) Electronics:

- Common in manufacturing of devices like computers, mobile phones and appliances. -

Ensures proper electrical conductivity while keeping components securely in place.

2) Jewelry making:

- Used for joining small metal parts without damaging delicate materials. - Ideal for creating
intricate designs and repairs.

3) Plumbing:

- Joining copper pipes and fittings in water supply and heating systems. - Provides water tight
and corrosion-resistant seals.

4) Automotive industry:

- Assembling electrical wiring, connectors and sensors. - Ensures secure connections in

vehicular control systems.

5) Aerospace industry

- For joining sensitive components in avionics and communication systems. - Creates precise
and reliable connections in harsh environment.

6) Medical Equipment manufacturing:

- Used to assemble intricate components in medical devices like pacemakers, diagnostic tools
and imaging equipment. - Ensures reliability and precision in life saving equipment.
Application of brazing in industries
1.​ Automotive industry:
●​ Joining parts of radiators, heat exchangers and fuel systems.
●​ Used in manufacturing gears, engine components and exhaust options.
1.​ Aerospace industry:
●​ Joining turbine blades, heat-resistant materials and complex engine parts.
●​ Ensures high strength and thermal stability for aircraft and spacecraft.
3) HVAC(Heating, Ventilation and Air Conditioning):
●​ Assembling copper and aluminum components in air conditioning and refrigeration
systems.
●​ Creates durable joints that withstand pressure and temperature variations.

4) Metalworking and Tool Making:

●​ Fabricating cutting tools, carbide tips and machine components.
●​ Allows joining dissimilar metals for enhanced tool performance.

5) Construction and infrastructure:

●​ Used for joining steel reinforcements and structural components.
●​ Applications in bridges, railings and architectural frameworks.

6) Electrical industry:
●​ Manufacturing transformers, bus bars and switchgear systems.
●​ Ensures efficient electrical conductivity in high-voltage systems.

Comparison between Soldering and

Brazing
Aspect

Soldering

Brazing

Temperature range

Operates below 450°C

Operates above 450°C

Filter material
Uses solder alloys(e.g. tin-lead)

Uses filter metals(e.g. brass, silver)

Joint strength

Produces weaker joints, suitable for low load applications

Produces stronger joints, suitable for high stress applications

Applications

Common in electronics, plumbing and jewelry

Use in automotive, aerospace, HVAC, etc.

Temperature effects

Lower thermal stress on components due to lower working temperature

Higher thermal stress due to elevated working temperature

Precision

Suitable for small, precise joints like circuit boards

Used for larger, stronger joints, often in industrial systems.

Leak proofing

Provides good leak-proofing for low-pressure systems

Excellent leak-proofing for high-pressure and high-temperature systems

Cost

Generally less expensive due to lower energy requirements

Can be more expensive due to higher energy use