Welding is a broad theme with many possible techniques that can be used and each one has its strengths and every technique fits something most of the time. Braze Welding – A Unique Take Though arc welding and its siblings today rule the metal joining realm, braze welding provides a different grill from which to smell that steak.
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Overview of Braze Welding – Process, Advantages & Applications In this blog post, let’s talk about braze welding in general and understand the process behind it as well…medium.com
A Different Kind of Bond
While fusion welding tends to melt the base metals together permanently, braze welding takes a different route. In this case, the base metals are heated to a temperature below their melting point. This is then followed by a distinct metal alloy, which contains base metals at lower melting points. This filler metal melts and takes a capillary action into the joint to form mechanical join between two-to-two mating parts.
Basic braze welding process consists of the following steps:
Preparation – The same as with other welding methods, preparation is a key part. Dirty: Surfaces must be well cleaned of any dirt, grease or oxides that could impede the flow of braze filler material in order to achieve a consistent joint.
Fluxing: In braze welding, applying a flux is key. A flux is a paste, liquid or powder that serves as the cleaning agent. When the brazing filler metal is melting, metallic oxides formed on base-metal surfaces are being dissolved by molten flux to provide a clean and strong connection.
The base metals are then heated through: oxy-fuel torches, induction heating or even resistance brazing with electrical current. The characteristic heating system relies on the application and also on metals being used.
2)Introduce the Filler Metal: The brazing filler metal is then introduced when both of these parent metals reach proper bonding temperatures (usually between 600 °C and 900 °C). The filling material is a rod, wire or even paste.
Capillary Action and Joining: The molten filler metal is drawn by capillarity into the closely fitted joint between faying surfaces of base metals. It is the capillary action that forces the filler metal into every nook and cranny of a joint, which results in excellent bond strength as it cools.
Trimming: After the joint cools, excess brazing material is removed with appropriate tools. The strength of the bond can sometimes be rated, and then subject to further cleaning or finishing depending on its downstream application.
The Allure of Braze Welding:
There are several benefits to braze welding that make it a worthwhile technique for many industries.
Dissimilar Metal Joining: Unlike some fusion welding such as gas hot crackers which is often limited to the joining of similar metals, braze welding does well in dissimilar metal join. It is an excellent solution for applications that involve the integration of different materials with specific properties.
Lower Heat Input: Brazing requires temperatures much lower than for fusion welding. As it minimizes distortion and warping in the base metals this makes plasma cutting ideal for thinner materials or where tight tolerance features are required.
Strength and Ductility: Although at lower temperatures, the joints made by brazing are actually surprisingly strong and ductile. The selection of the right brazing filler metal is critical to making certain that these strength and ductility properties are met.
Aesthetic Joints and Malleability: Brazing also results in a clean, aesthetic joint that allows for better malleable properties within the connected materials. The lower heat input reduces the discoloration and oxidation of the base metals, which is desired for some applications where appearance counts.
Caveats and Considerations:
Braze welding is a strong method itself, as I have mentioned earlier but there are some limitation which needs to consider all of us:
Strengths: Generally lower compared to fusion weld strength in brazed joints. This is because the joint depends only on the physical bond of melted filler metal and does not require melting or fusing together of base metals.
The Fit Of The Joints. -Braze welding is a capillary action so, the joints must be soldered with an excellent amount of brazing liquid and hence requires very tightly fit joint designs for best results in bonding strength. Brazing does not work as well between large gaps in components, unlike fusion welding.
Labor-Intensive: Brazing operation is simple enough, although, in order to master the process correctly and achieve repeatable results, one must have practice as well an understanding on how metals behave at extreme temperature.
Applications of Braze Welding in the Real World
Due to the following advantages, Braze welding is used in many of industries:
Some examples include: * Plumbing and HVAC – Brazing is the primary method for joining copper pipes and components in plumbing as well as heating, ventilation, air condition (HVAC) systems. It is also able to join different metals and the clean look of the joints, it is the best suitable.
Automotive: In automotive applications, brazing is used in everything from joining radiator parts to assembly of complex transmission and differential modules. Less heat into the part means less distortion/less warping of critical components.
Aerospace: Aerospace manufacturing can use braze joining honeycomb structures, heat exchangers.