BRAZING: (CHAPTER
8.7)
Prepared by: Aarogya Parajuli.
TOPICS OF
DISCUSSION:
BRAZING INTRODUCTION
(page 03)
CLEANING AND HEATING
(page 04-page 05)
FILLER METAL
APPLICATION
(page 06)
FLUX APPLICATION
(page 07 – page 08)
CLEARING AFTER BRAZING
(page 09 – page 10)
05/29/2025 PREPARED BY : AAROGYA PARAJULI (ACE080BCT003) 2
BRAZING:
INTRODUCTION
Brazing is a metal-joining process that uses heat
to join two or more pieces of metal together. It is
often used as an alternative to welding when
welding is not possible or practical due to the
material’s physical characteristics. A unique
quality in the brazing process is that it keeps the
mechanical properties of the metals which are
useful in applications such as silver brazing or
other similar metals.
PREPARED BY : AAROGYA PARAJULI
05/29/2025 2
(ACE080BCT003)
CLEANING
Parts to be joined must be cleaned and
degreased. The presence of contaminants
such as oxides, paint, grease/oil and any
other form of contamination, will affect the
final result, giving rise to brittle joints and
potentially to dangerous metal fumes.
05/29/2025 PREPARED BY : AAROGYA PARAJULI (ACE080BCT003) 4
HEATING
• Manual brazing is usually performed with acetylene torches
or with other fuel gases like propane, methane or hydrogen.
Torch brazed joints must reach the melting temperature of
the filler metal as quickly as possible, to avoid
microstructural changes of the material. The brazing process
must be completed in a suitable time with regard to the flux
life. The latter is limited both by temperature and heating
time; beyond these limits, the flux will be saturated with
oxides and its effectiveness will decrease.
• During the heating stage, the joint area should be heated
uniformly. If the components have different thicknesses, the
part with the greater weight is heated first. When the
materials have a different thermal conductivity, it is
advisable to heat first the component with the lower
conductivity, since it absorbs less heat.
• If the heating is insufficient or there is a thermal difference
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between the components, the overlapping area will be 5
PREPARED BY : AAROGYA PARAJULI (ACE080BCT003)
brazed in a discontinuous way, giving rise to a brittle joint.
FILLER METAL
APPLICATIONS
The filler metal used in brazing is an alloy of copper and zinc. This
copper-zinc alloy, known as brass, melts around 900-950°F (480-
510°C). When heated to its melting point, brass flows into the
gap between two pieces of metal that need to be joined, creating
a strong bond between them. In addition to brass alloys, some
brazing filler metals are also made with silver or nickel for special
applications.
When it comes to selecting a filler metal for brazing, several
factors need to be considered:
These include the materials being joined, joint design and
clearance, application temperatures and environmental
conditions, cost considerations, corrosion resistance, and
strength requirements. The type of filler metal chosen should
match all these requirements to ensure a successful joint.
Filler metals must achieve proper wetti ng conditions in order
to create strong bonds.
PREPARED BY : AAROGYA
05/29/2025 6
PARAJULI (ACE080BCT003)
WHAT IS FLUX ?
A flux is a chemical compound to dissolve oxides formed on
surface of the metal or filler rod.
Any form of the oxides on the surface of the metal when
heated will prevent the uniform flow of the brazing metals.
For this reason, flux is necessary to eliminate the oxide.
FLUX APPLICATION HOW TO APPLY FLUX TO JOINTS?
Typically you apply the flux just before brazing, if
possible. That way the flux has least chance to dry out
and flake off, or get knocked off the parts in handling.
As for the how, apply the flux any way you can as long
as you cover the surfaces completely.
Since flux is conventionally made in a paste
consistency, it's usually most convenient to brush it on.
But as production quantities increase, it may be more
effi cient to apply the flux by dipping or dispensing a
pre-measured deposit of high viscosity dispensable flux
from an applicator gun
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ACIDS, ALKALIS, FLUOROBORATES, FUSED
WETTING FLUORIDES, BORATE
BORAX
AGENTS CHLORIDES S
BRAZING FLUX
INGREDIENTS
THESE INGREDIENTS MAY VARY AS PER
BRAZING REQUIREMENT
FLUX
PREPARED BY : AAROGYA PARAJULI
CLEARING AFTER BRAZING WHY TO CLEAR BRAZING
RESIDUE ?
FLUX RESIDUES ARE CHEMICALLY CORROSIVE
AND, IF NOT REMOVED, COULD WEAKEN
CERTAIN JOINTS.
SOME WAYS OF POST-BRAZING
CLEARING:
• Soaking/wetting - Use hot water with agitation in a soak
tank to remove excess flux immediately following the
braze operation, and then dry the assembly. When soaking
is not possible, use a wire brush along with a spray bottle
or wet towel.
• Quenching - This process induces a thermal shock that
cracks off residual flux. When quenching a brazed part in
hot water, take care to avoid compromising the braze joint.
Quench only after the braze filler metal has solidified to
avoid cracks or rough braze joints. Note that quenching
can affect base material mechanical properties. Do not
quench materials with large differences in coefficients of
thermal expansion to avoid cracks in the base materials
and tears within
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the braze alloy.
PREPARED BY : AAROGYA PARAJULI (ACE080BCT003) 9
• Steam lance cleaning - This process
employs super-heated steam under
pressure to dissolve and blast away
flux residue.
• Mechanical cleaning - Clean residue
from brazed joints with a wire brush
or by sandblasting. Be advised that
soft metals-including aluminium-
require extra care, as they are
vulnerable to the embedding of
particles.
• Chemical cleaning - You can use an
acidic or basic solution, generally
with short soak times to avoid
deteriorating the base materials.
05/29/2025 PREPARED BY : AAROGYA PARAJULI (ACE080BCT003) 10
YOUR PATIENCE AND
UNDERSTANDING ARE
GREATLY APPRECIATED !
WE HOPE YOU HAVE UNDERSTOOD THE
TOPIC BRAZING.
05/29/2025 PREPARED BY : AAROGYA PARAJULI (ACE080BCT003) 11
THANK YOU !
Presentation prepared by: Aarogya
Parajuli.
Submitted to: Department of
05/29/2025
Applied Science
PREPARED BY : AAROGYA PARAJULI (ACE080BCT003) 12
