Department of Mechanical Engineering
ME-303L Manufacturing Processes Lab
Experiment No. 05
Experiment Name: Part Manufacturing by using Brazing Technique
Name of Student: Muhammad Umair
Registration No.: 04-3-1-036-2022
Date of Experiment: 07-04-2025
Group: B2
Report Marks ______ out of 10
Date of Report Submission: 15-05-2025
Signature of Lab Engineer:
Table of Contents
1. Abstract…………………………………………………………………………………………1
2. Introduction……………………………………………………………………………………..1
3. Procedure………………………………………………………………………………………..3
4. Discussion………………………………………………………………………………………3
5. Conclusion……………………………………………………………………………………….4
6. References………………………………………………………………………………………4
List of Figures
Figure 1: Oxygen and Acetylene Cylinders used for Brazing ................................................................. 2
Figure 2: Braze Welding ......................................................................................................................... 2
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Abstract
This experiment investigated the brazing process, a metal-joining technique that uses a filler
metal with a melting point above 450°C but below the melting temperature of the base metals.
The study examined critical factors such as joint preparation, filler metal selection, flux
application, and heating methods to achieve a strong, durable bond. Mild steel specimens
were joined using a copper-based filler rod and an oxy-acetylene torch under controlled
conditions. The results demonstrated that brazing produces high-strength, leak-proof
joints while allowing the joining of dissimilar metals—an advantage over traditional welding.
Proper surface cleaning, flux application, and temperature control were essential for successful
joint formation.
Introduction
Brazing is a widely used metal-joining process that creates strong, permanent bonds without
melting the base materials. Unlike welding, which requires the base metals to reach their
melting points, brazing relies on a lower-melting-point filler metal that flows into the joint
via capillary action, forming a metallurgical bond upon cooling. This technique is particularly
valuable in industries requiring precision, corrosion resistance, and the ability to join
dissimilar metals, such as HVAC, automotive, and aerospace engineering[1].
The brazing process depends on several key factors:
• Joint design – A controlled gap (0.025–0.15 mm) ensures proper capillary flow of the
filler metal.
• Surface preparation – Cleaning with a wire brush or emery paper removes oxides and
contaminants that could weaken the bond.
• Flux application – A borax-based flux prevents oxidation and enhances wetting of
the filler metal.
• Heating method – An oxy-acetylene torch provides precise, localized heating to melt
the filler without overheating the base metals.
Brazing is especially useful for joining dissimilar metals (e.g., copper to steel) where welding
would be impractical due to differences in melting points or thermal expansion. The resulting
joints exhibit excellent mechanical strength, electrical conductivity, and thermal stability,
making brazing a preferred method in high-performance applications[2].
Materials & Equipment
• Base Metals: Mild steel specimens (cleaned with emery paper)
• Filler Metal: Brass or copper-based brazing rod (melting range: 600–900°C)
• Flux: Borax-based paste (to prevent oxidation and improve adhesion)
• Heating Source: Oxy-acetylene torch (for controlled, localized heating)
• Clamping Devices: To maintain proper alignment during brazing
• Safety Equipment: Heat-resistant gloves, welding goggles, apron, and fume
ventilation
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Figure 1: Oxygen and Acetylene Cylinders used for Brazing
Figure 2: Braze Welding
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Procedure
The metal surfaces to be joined were cleaned using emery paper and a wire brush to remove rust,
dirt, and grease. Proper cleaning ensures a strong bond by allowing the filler metal to wet the surfaces
effectively.
A thin layer of borax-based flux was applied to the joint area. The flux prevents oxidation during
heating and aids the smooth flow of the filler metal.
The base metal pieces were properly aligned and securely clamped to maintain their position during
heating and filler application.
An oxy-acetylene gas torch was used to heat the joint area uniformly. Care was taken to avoid directly
melting the base metal.
As the joint area reached the appropriate temperature, the brazing rod (filler metal) was introduced.
The filler melted and flowed into the joint through capillary action.
After removing the heat source, the joint was allowed to cool naturally. Excess flux residue was
removed using water and a wire brush.
3. Discussion
The experiment successfully demonstrated the brazing process, emphasizing the critical role
of surface preparation, flux application, and controlled heating in achieving a strong joint.
Proper cleaning of the base metals ensured effective wetting by the filler metal, while
the borax-based flux prevented oxidation and facilitated smooth capillary flow into the joint.
The oxy-acetylene torch provided precise, localized heating—sufficient to melt the filler
metal without overheating the base materials. Maintaining uniform heat distribution was
essential; excessive heat could degrade the metal, while insufficient heat would impair filler
flow. The resulting joint exhibited good mechanical strength and a clean appearance,
confirming brazing’s effectiveness for both similar and dissimilar metals. Additionally, the
process proved to be energy-efficient and environmentally friendly, especially when
compared to high-temperature welding techniques.
Advantages of Brazing
• Joins dissimilar metals (e.g., copper to steel) without melting base materials.
• Produces clean, precise joints with minimal post-processing required.
• Lower energy consumption compared to welding (reduced thermal distortion).
• Ideal for thin or delicate components that cannot withstand welding stresses.
• Suitable for mass production due to repeatability and speed.
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Disadvantages of Brazing
• Lower joint strength than welded connections (not suitable for heavy load-bearing
applications).
• Limited high-temperature resistance—brazed joints may fail under extreme heat.
• Requires meticulous surface preparation (cleaning, fluxing) for optimal bonding.
• Aesthetic mismatch—filler metal color may differ from base metals.
Conclusion
This experiment provided a practical understanding of the brazing process, including joint
preparation, filler metal selection, and heat application. The results confirmed that brazing
is a versatile and efficient method for joining metals, particularly where precision, minimal
distortion, and dissimilar metal compatibility are required. While brazing has some
limitations in strength and high-temperature performance, its advantages in cleanliness,
energy efficiency, and ease of use make it a valuable technique in industries such as HVAC,
automotive, and electronics. Proper execution—emphasizing surface cleanliness, flux
application, and controlled heating—is essential for achieving reliable, high-quality brazed
joints.
1. References
[1] M. P. Groover, Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, 6th
ed. Hoboken, NJ, USA: Wiley, 2016.
[2] "Basics of Brazing," The Welding Institute (TWI), [Online]. Available: https://www.twi-
global.com/technical-knowledge/job-knowledge/brazing-basics-066
[3] "Introduction to Brazing," Lucas-Milhaupt, Inc., [Online]. Available:
https://www.lucasmilhaupt.com/en-US/knowledge-center/brazing-introduction/
