Brazing is a metal-joining process in which two or more metal items are joined by melting and flowing a filler
metal into the joint, with the filler metal having a lower melting point than the adjoining metal.
Brazing differs from welding in that it does not involve melting the work pieces. Brazing differs
from soldering through the use of a higher temperature and much more closely fitted parts than when
soldering. During the brazing process, the filler metal flows into the gap between close-fitting parts by capillary
action ( the process of a liquid flowing in a narrow space in opposition to or at least without the assistance of
any external forces like gravity.)
Brazing is a metal joining in which the filler metal is a nonferrous metal or alloy whose melting point. is
higher than I000°F., but is lower than that of the metals or alloys being joined.
The temperature of the joint must be greater than the melting point of metals. So here in the case of brazing,
the temperature of the joint must be greater than 450-degree centigrade.
In general, copper brazing is high-temperature brazing (above 1600°F.); and silver brazing is low-
temperature brazing (1175-1600°F.)
It is a process of joining similar or dissimilar metals using filler material. The filler material is called Spelter and
the filler material is made up of Copper alloy.( the molten metals copper, zinc alloy is having the highest
capillary action. hence, it is used as a filler rod in the brazing operation.)
(A mixture of Spelter and Borax with Water is used as a paste and is applied to the metal parts at the joints.)
Brazing Process:
First, you need to take two workpieces to join them through the process of brazing. As in the case of soldering,
we had used a soldering gun and filler material for the formation of joint whereas, in the Brazing process, a
paste is used, which is the mixture of (Spelter+Borax+Water) and is to be applied on to the work region.
The type of joint formed is Permanent and the load bearing capability is also high.
Later, the applied material has to be heated so that it can melt and form as a layer in between two workpieces.
Here, Oxy-Acetylene gas welding is used to heat the mixture for the formation of joints, and the Copper
alloys are used as a filler rod.
Applications of Brazing Process:
The applications of Brazing are as follows.
Brazing is used for the fastening of pipe fittings, carbide tips on tools, heat exchangers, electrical parts,
radiators, axles, etc.
It can join cast metals to wrought metals, dissimilar metals, porous metal components, etc.
It is used to join parts of the bicycle such as frame and rims.
Advantages of Brazing
1. Since brazing does not melt the base metal of the joint, it allows much tighter control over tolerances
and produces a clean joint without the need for secondary finishing & keeping their shape and
mechanical properties.
2. Dissimilar metals and non-metals (i.e. metalized ceramics) can be brazed.
3. Brazing also produces less thermal distortion than welding due to the uniform heating of a brazed
piece.
4. Complex and multi-part assemblies can be brazed cost-effectively.
5. Brazing can be coated or clad for protective purposes.
6. Brazing is easily adapted to mass production.
7. Consumes less power than welding.
Disadvantages of Brazing
1. One of the main disadvantages is the lack of joint strength as compared to a welded joint due to the
softer filler metals used.
2. Brazed joints can be damaged under high service temperatures.
3. Brazed joints require a high degree of base-metal cleanliness - exceptionally clean and free of oxides.
* In most cases, joint clearances of 0.03 to 0.08 mm (0.0012 to 0.0031 in) are recommended for the
best capillary action and joint strength.
*The two main methods for cleaning parts, prior to brazing, are chemical cleaning and abrasive or
mechanical cleaning.
Soldering Process
It is a process of joining similar or dissimilar metals using filler material. The filler material is called
as Solder and the filler material is made up of Lead-Tin alloy.
During soldering, there is a need for flux which is made up of Zinc Chloride, Ammonium Chloride, and resin is
mixed with them.
The mechanism of the joint is Wetting and Surface Alloying.
Type of Joint: Temporary.
Load bearing capability: less than Brazing
Here in the case of soldering, the temperature of the joint must be less than 450-degree centigrade.
Working Principle of Soldering Process:
First, the Soldering gun is to be heated up to the desired temperature. Now, the filler metal has to be in contact
with the soldering gun with which the filler metal melts and deposits on the work region.
When the (50% lead & 50% Tin Alloy) is to be heated to a temperature greater than 450-degree centigrade,
the tin present in the lead & Tin alloy starts evaporating. Hence the temperature of the joint must be <450
Degree centigrade.
The melted filler metal enters into the work region by the action of capillarity and after cooling, the joint is
formed.
Advantages of Soldering Process:
The advantages of Soldering process are as follows.
Joints prepared using the soldering process will be dismantled easily.
Soldering can be done at a low temperature of less than Brazing operation.
The soldering cost is very less.
It's simple in design and economical.
Disadvantages of Soldering Process:
The disadvantages of Soldering process are as follows.
Skilled worker is required to make a perfect and stronger joint.
Solders are costlier.
Soldering can be applied only for small joints but it cannot be applied for heavy parts.
Applications of Soldering Process:
Mostly used to solder the wires on the Printed Circuit Boards(PCB).
Soldering V/S Brazing:
The comparison chart of Soldering vs Brazing was presented below.
Soldering Brazing
The boiling point of filler material is below
The boiling point of filler material is above 450°C.
450°C.
The filler material is called as Solder. The filler material is called as Spelter.
The filler material is made up of Lead-Tin
alloy. The filler material is made up of Copper alloy.
Filler Rod: (50% lead & 50% Tin Alloy)
It is a Temperory joint. It is a Temperory joint.
The strength at the joint is very less The strength of the material after brazing is very
compared to the Brazing. high comapred to Soldering.
The preheating is not required for the base
The preheating is required for the base metal.
metal.
The setup cost is very small compared to
The setup cost is very high compared to brazing.
brazing.
It's simple in design and economical. It is not economical.
Applications: It is mostly used in Printed Applications: It is mostly used in all kinds of metals,
Circuit boards (PCB's) pipe fittings etc.
Copper-base alloy brazing, silver brazing, and aluminum brazing are all used in
aircraft work. Soldering is never used
for structural purposes but is frequently used in electrical work
BRAZING OF ALUMINUM
The brazing material itself is an aluminum/silicon alloy. Aluminum brazing occurs at temperatures over 875 °F,
but below the melting point of the parent metal. Brazing is best suited to joint configurations that have large
surface areas in contact, such as the lap, or for fitting fuel tank bungs and fittings.
Using eye protection that reduces the sodium flare, such as the TM2000 lens, is recommended.
Brazing is more easily accomplished on 1100, 3003, and 6061 aluminum alloys. 5052 alloy is more difficult;
proper cleaning and practice are vital.
The flux is corrosive, so every effort should be made to remove it thoroughly and quickly after the brazing is
completed.
