NOTIUNI FUNDAMENTALE PRIVIND BRAZAREA

PROCESUL DE BRAZARE
Brazing is a metal-joining process whereby a filler metal is heated above melting
point and distributed between two or more close-fitting parts by capillary action.
The filler metal is brought slightly above its melting (liquidus) temperature while
protected by a suitable atmosphere, usually a flux. t then flows over the base metal
(!nown as wetting) and is then cooled to join the wor!pieces together.
"#$
t is
similar to soldering, except the temperatures used to melt the filler metal are
higher.
n order to obtain high-quality bra%ed joints, parts must be closely fitted, and the
base metals must be exceptionally clean and free of oxides. n most cases, joint
clearances of &.&' to &.&( mm are recommended for the best capillary action and
joint strength.
")$
*owever, in some bra%ing operations it is not uncommon to have
joint clearances around &.+ mm (&.&), in). -leanliness of the bra%ing surfaces is
also important, as any contamination can cause poor wetting (flow). The two main
methods for cleaning parts, prior to bra%ing are chemical cleaning, and abrasive or
mechanical cleaning. n the case of mechanical cleaning, it is important to maintain
the proper surface roughness as wetting on a rough surface occurs much more
readily than on a smooth surface of the same geometry.
")$
.nother consideration that cannot be overloo!ed is the effect of temperature and
time on the quality of bra%ed joints. .s the temperature of the bra%e alloy is
increased, the alloying and wetting action of the filler metal increases as well. n
general, the bra%ing temperature selected must be above the melting point of the
filler metal. *owever, there are several factors that influence the joint designer/s
temperature selection.
The best temperature is usually selected so as to0
be the lowest possible bra%e temperature,
minimi%e any heat effects on the assembly,
!eep filler metal1base metal interactions to a minimum,
maximi%e the life of any fixtures or jigs used.
")$

n some cases, a higher temperature may be selected to allow for other factors in
the design (e.g. to allow use of a different filler metal, or to control metallurgical
effects, or to sufficiently remove surface contamination). The effect of time on the
bra%ed joint primarily affects the extent to which the aforementioned effects are
present2 however, in general most production processes are selected to minimi%e
bra%ing time and the associated costs. This is not always the case, however, since
in some non-production settings, time and cost are secondary to other joint
attributes (e.g. strength, appearance).
FLUXURILE LA BRAZARE
n the case of bra%ing operations not contained within an inert or reducing
atmosphere environment (i.e. a furnace), flux is required to prevent oxides from
forming while the metal is heated. The flux also serves the purpose of cleaning any
contamination left on the bra%ing surfaces. 3lux can be applied in any number of
forms including flux paste, liquid, powder or pre-made bra%ing pastes that combine
flux with filler metal powder.
3lux can also be applied using bra%ing rods with a coating of flux, or a flux core.
n either case, the flux flows into the joint when applied to the heated joint and is
displaced by the molten filler metal entering the joint. 4xcess flux should be
removed when the cycle is completed because flux left in the joint can lead to
corrosion, impede joint inspection, and prevent further surface finishing
operations. 5hosphorus-containing bra%ing alloys can be self-fluxing when joining
copper to copper.
"'$
3luxes are generally selected based on their performance on
particular base metals. To be effective, the flux must be chemically compatible
with both the base metal and the filler metal being used. 6elf-fluxing phosphorus
filler alloys produce brittle phosphides if used on iron or nic!el.
"'$
.s a general
rule, longer bra%ing cycles should use less active fluxes than short bra%ing
operations.
",$
MATERIALELE DE ADAOS LA BRAZARE
. variety of alloys are used as filler metals for bra%ing depending on the intended
use or application method. n general, bra%e alloys are made up of ' or more
metals to form an alloy with the desired properties. The filler metal for a particular
application is chosen based on its ability to0 wet the base metals, withstand the
service conditions required, and melt at a lower temperature than the base metals
or at a very specific temperature.
7ra%e alloy is generally available as rod, ribbon, powder, paste, cream, wire and
preforms (such as stamped washers).
"8$
9epending on the application, the filler
material can be pre-placed at the desired location or applied during the heating
cycle. 3or manual bra%ing, wire and rod forms are generally used as they are the
easiest to apply while heating. n the case of furnace bra%ing, alloy is usually
placed beforehand since the process is usually highly automated.
",, 8, +$
6ome of the
more common types of filler metals used are
.luminum-silicon
-opper
-opper-silver
-opper-%inc (brass)
:old -silver
;ic!el alloy
6ilver
"#$

"+$

.morphous bra%ing foil using nic!el, iron, copper, silicon, boron,
phosphorus, etc.
6ome bra%es come in the form of trifoils, laminated foils of a carrier metal clad with a layer of
bra%e at each side. The center metal is often copper2 its role is to act as a carrier for the alloy, to
absorb mechanical stresses due to e.g. differential thermal expansion of dissimilar materials (e.g.
a carbide tip and a steel holder), and to act as a diffusion barrier (e.g. to stop diffusion of
aluminium from aluminium bron%e to steel when bra%ing these two).
FAMILII DE ALIAE PENTRU BRAZARE
7ra%ing alloys form several distinct groups2 the alloys in the same group have similar properties
and uses.
"#,$
P!r" #"tals0 <nalloyed. =ften noble metals > silver, gold, palladium.
Ag$C!0 :ood melting properties. 6ilver enhances flow. 4utectic alloy used for furnace
bra%ing. -opper-rich alloys prone to stress crac!ing by ammonia.
Ag$Zn0 6imilar to -u-?n, used in jewelry due to high silver content to be compliant with
hallmar!ing. -olor matches silver. @esistant to ammonia-containing silver-cleaning
fluids.
C!$Zn (brass)0 :eneral purpose, used for joining steel and cast iron. -orrosion resistance
usually inadequate for copper, silicon bron%e, copper-nic!el, and stainless steel.
@easonably ductile. *igh vapor pressure due to volatile %inc, unsuitable for furnace
bra%ing. -opper-rich alloys prone to stress crac!ing by ammonia.
Ag$C!$Zn0 Aower melting point than .g--u for same .g content. -ombines advantages
of .g--u and -u-?n. .t above ,&B ?n the ductility and strength drop, so only lower-
%inc alloys of this type are used. .t above )8B %inc less ductile copper-%inc and silver-
%inc phases appear. -opper content above +&B yields reduced strength and liquidus
above C&& D-. 6ilver content above (8B yields reduced strength, high liquidus and high
cost. -opper-rich alloys prone to stress crac!ing by ammonia. 6ilver-rich bra%es (above
+E.8B .g) are hallmar!able and used in jewellery2 alloys with lower silver content are
used for engineering purposes. .lloys with copper-%inc ratio of about +&0,& contain the
same phases as brass and match its color2 they are used for joining brass. 6mall amount
of nic!el improves strength and corrosion resistance and promotes wetting of carbides.
.ddition of manganese together with nic!el increases fracture toughness. .ddition of
cadmium yields Ag$C!$Zn$C% alloys with improved fluidity and wetting and lower
melting point2 however cadmium is toxic. .ddition of tin can play mostly the same role.
C!$P0 Fidely used for copper and copper alloys. 9oes not require flux for copper. -an
be also used with silver, tungsten, and molybdenum. -opper-rich alloys prone to stress
crac!ing by ammonia.
Ag$C!$P0 Ai!e -u-5, with improved flow. 7etter for larger gaps. Gore ductile, better
electrical conductivity. -opper-rich alloys prone to stress crac!ing by ammonia.
A!$Ag0 ;oble metals. <sed in jewelry.
A!$C!0 -ontinuous series of solid solutions. @eadily wet many metals, including
refractory ones. ;arrow melting ranges, good fluidity.
"#8$
3requently used in jewellery.
.lloys with ,&>C&B of gold harden on cooling but stay ductile. ;ic!el improves
ductility. 6ilver lowers melting point but worsens corrosion resistance2 to maintain
corrosion resistance gold has to be !ept above +&B. *igh-temperature strength and
corrosion resistance can be improved by further alloying, e.g. with chromium, palladium,
manganese and molybdenum. .ddition of vanadium allows wetting ceramics. Aow vapor
pressure.
A!$Ni0 -ontinuous series of solid solutions. Fider melting range than .u--u alloys but
better corrosion resistance and improved wetting. 3requently alloyed with other metals to
reduce proportion of gold while maintaining properties. -opper may be added to lower
gold proportion, chromium to compensate for loss of corrosion resistance, and boron for
improving wetting impaired by the chromium. :enerally no more than '8B ;i is used, as
higher ;i1.u ratios have too wide melting range. Aow vapor pressure.
A!$P%0 mproved corrosion resistance over .u--u and .u-;i alloys. <sed for joining
superalloys and refractory metals for high-temperature applications, e.g. jet engines.
4xpensive. Gay be substituted for by cobalt-based bra%es. Aow vapor pressure.
P%0 :ood high-temperature performance, high corrosion resistance (less than gold), high
strength (more than gold). usually alloyed with nic!el, copper, or silver. 3orms solid
solutions with most metals, does not form brittle intermetallics. Aow vapor pressure.
Ni0 ;ic!el alloys, even more numerous than silver alloys. *igh strength. Aower cost than
silver alloys. :ood high-temperature performance, good corrosion resistance in
moderately aggressive environments. =ften used for stainless steels and heat-resistant
alloys. 4mbrittled with sulfur and some lower-melting point metals, e.g. %inc. 7oron,
phosphorus, silicon and carbon lower melting point and rapidly diffuse to base metals2
this allows diffusion bra%ing and allows the joint to be used above the bra%ing
temperature. 7orides and phosphides form brittle phases2 amorphous preforms can be
made by rapid solidification.
Co0 -obalt alloys. :ood high-temperature corrosion resistance, possible alternative to
.u-5d bra%es. Aow wor!ability at low temperatures, preforms prepared by rapid
solidification.
Al$Si0 for bra%ing aluminium.
A&ti'" allo(s0 -ontaining active metals, e.g. titanium or vanadium. <sed for bra%ing
non-metallic materials, e.g. graphite or ceramics.
Rol" of "l"#"nts
"l"#"nt rol" 'olatilit(
&orrosion
r"sistan&"
&ost
In&o
#)ati*ilit(
%"s&ri)tion
Sil'"r structural, volatile expensive 4nhances capillary flow,
"l"#"nt rol" 'olatilit(
&orrosion
r"sistan&"
&ost
In&o
#)ati*ilit(
%"s&ri)tion
wetting
improves corrosion
resistance of less-noble
alloys, worsens corrosion
resistance of gold and
palladium. @elatively
expensive. *igh vapor
pressure, problematic in
vacuum bra%ing. Fets
copper. 9oes not wet nic!el
and iron. @educes melting
point of many alloys,
including gold-copper.
Co))"r structural ammonia
:ood mechanical properties.
=ften used with silver.
9issolves and wets nic!el.
6omewhat dissolves and
wets iron. -opper-rich alloys
sensitive to stress crac!ing in
presence of ammonia.
Zin&
structural,
melting,
wetting
volatile low cheap ;i
Aowers melting point. =ften
used with copper.
6usceptible to corrosion.
mproves wetting on ferrous
metals and on nic!el alloys.
-ompatible with aluminium.
*igh vapor tension, produces
somewhat toxic fumes,
requires ventilation2 highly
volatile above 8&& D-. .t
high temperatures may boil
and create voids. 5rone to
selective leaching in some
environments, which may
cause joint failure. Traces of
bismuth and beryllium
together with tin or %inc in
aluminium-based bra%e
destabili%e oxide film on
aluminium, facilitating its
wetting. *igh affinity to
oxygen, promotes wetting of
copper in air by reduction of
the cuprous oxide surface
film. Aess such benefit in
furnace bra%ing with
controlled atmosphere.
4mbrittles nic!el. *igh
levels of %inc may result in a
brittle alloy."8$
Al!#ini!# structural, 3e <sual base for bra%ing
"l"#"nt rol" 'olatilit(
&orrosion
r"sistan&"
&ost
In&o
#)ati*ilit(
%"s&ri)tion
active
aluminium and its alloys.
4mbrittles ferrous alloys.
+ol%
structural,
wetting
excellent
very
expensive
4xcellent corrosion
resistance. Hery expensive.
Fets most metals.
Palla%i!# structural excellent
very
expensive
4xcellent corrosion
resistance, though less than
gold. *igher mechanical
strength than gold. :ood
high-temperature strength.
Hery expensive, though less
than gold. Ga!es the joint
less prone to fail due to
intergranular penetration
when bra%ing alloys of
nic!el, molybdenum, or
tungsten.
"E$
ncreases high-
temperature strength of gold-
based alloys."+$ mproves
high-temperature strength
and corrosion resistance of
gold-copper alloys. 3orms
solid solutions with most
engineering metals, does not
form brittle intermetallics.
*igh oxidation resistance at
high temperatures, especially
5d-;i alloys.
Ca%#i!#
structural,
wetting,
melting
volatile toxic
Aowers melting point,
improves fluidity. Toxic.
5roduces toxic fumes,
requires ventilation. *igh
affinity to oxygen, promotes
wetting of copper in air by
reduction of the cuprous
oxide surface film. Aess such
benefit in furnace bra%ing
with controlled atmosphere.
.llows reducing silver
content of .g--u-?n alloys.
@eplaced by tin in more
modern alloys.
L"a%
structural,
melting
Aowers melting point. Toxic.
5roduces toxic fumes,
requires ventilation.
Tin
structural,
melting,
wetting
Aowers melting point,
improves fluidity. 7roadens
melting range. -an be used
with copper, with which it
forms bron%e. mproves
"l"#"nt rol" 'olatilit(
&orrosion
r"sistan&"
&ost
In&o
#)ati*ilit(
%"s&ri)tion
wetting of many difficult-to-
wet metals, e.g. stainless
steels and tungsten carbide.
Traces of bismuth and
beryllium together with tin or
%inc in aluminium-based
bra%e destabili%e oxide film
on aluminium, facilitating its
wetting. Aow solubility in
%inc, which limits its content
in %inc-bearing alloys."8$
Bis#!t,
trace
additive
Aowers melting point. Gay
disrupt surface oxides.
Traces of bismuth and
beryllium together with tin or
%inc in aluminium-based
bra%e destabili%e oxide film
on aluminium, facilitating its
wetting."8$
B"r(lli!#
trace
additive
Traces of bismuth and
beryllium together with tin or
%inc in aluminium-based
bra%e destabili%e oxide film
on aluminium, facilitating its
wetting."8$
Ni&-"l
structural,
wetting
high ?n, 6
6trong, corrosion-resistant.
mpedes flow of the melt.
.ddition to gold-copper
alloys improves ductility and
resistance to creep at high
temperatures.",$ .ddition to
silver allows wetting of
silver-tungsten alloys and
improves bond strength.
mproves wetting of copper-
based bra%es. mproves
ductility of gold-copper
bra%es. mproves mechanical
properties and corrosion
resistance of silver-copper-
%inc bra%es. ;ic!el content
offsets brittleness induced by
diffusion of aluminium when
bra%ing aluminium-
containing alloys, e.g.
aluminium bron%es. n some
alloys increases mechanical
properties and corrosion
resistance, by a combination
of solid solution
"l"#"nt rol" 'olatilit(
&orrosion
r"sistan&"
&ost
In&o
#)ati*ilit(
%"s&ri)tion
strengthening, grain
refinement, and segregation
on fillet surface and in grain
boundaries, where it forms a
corrosion-resistant layer.
4xtensive intersolubility with
iron, chromium, manganese,
and others2 can severely
erode such alloys. 4mbrittled
by %inc, many other low
melting point metals, and
sulfur."8$
C,ro#i!# structural high
-orrosion-resistant. ncreases
high-temperature corrosion
and strength of gold-based
alloys. .dded to copper and
nic!el to increase corrosion
resistance of them and their
alloys.",$ Fets oxides,
carbides, and graphite2
frequently a major alloy
component for high-
temperature bra%ing of such
materials. mpairs wetting by
gold-nic!el alloys, which can
be compensated for by
addition of boron."8$
Mangan"s" structural volatile good cheap
*igh vapor pressure,
unsuitable for vacuum
bra%ing. n gold-based alloys
increases ductility. ncreases
corrosion resistance of
copper and nic!el alloys.",$
mproves high-temperature
strength and corrosion
resistance of gold-copper
alloys. *igher manganese
content may aggravate
tendency to liquation.
Ganganese in some alloys
may tend to cause porosity in
fillets. Tends to react with
graphite molds and jigs.
=xidi%es easily, requires
flux. Aowers melting point of
high-copper bra%es.
mproves mechanical
properties and corrosion
resistance of silver-copper-
%inc bra%es. -heap, even less
expensive than %inc. 5art of
"l"#"nt rol" 'olatilit(
&orrosion
r"sistan&"
&ost
In&o
#)ati*ilit(
%"s&ri)tion
the -u-?n-Gn system is
brittle, some ratios can not be
used."8$ n some alloys
increases mechanical
properties and corrosion
resistance, by a combination
of solid solution
strengthening, grain
refinement, and segregation
on fillet surface and in grain
boundaries, where it forms a
corrosion-resistant layer.
3acilitates wetting of cast
iron due to its ability to
dissolve carbon.
Mol(*%"n!# structural good
ncreases high-temperature
corrosion and strength of
gold-based alloys.",$
ncreases ductility of gold-
based alloys, promotes their
wetting of refractory
materials, namely carbides
and graphite. Fhen present
in alloys being joined, may
destabili%e the surface oxide
layer (by oxidi%ing and then
volatili%ing) and facilitate
wetting.
Co*alt structural good
:ood high-temperature
properties and corrosion
resistance. n nuclear
applications can absorb
neutrons and build up cobalt-
+&, a potent gamma radiation
emitter.
Magn"si!#
volatile =
)

getter
volatile
.ddition to aluminium
ma!es the alloy suitable for
vacuum bra%ing. Holatile,
though less than %inc.
Hapori%ation promotes
wetting by removing oxides
from the surface, vapors act
as getter for oxygen in the
furnace atmosphere.
In%i!#
melting,
wetting
expensive
Aowers melting point.
mproves wetting of ferrous
alloys by copper-silver
alloys.
Car*on melting
Aowers melting point. -an
form carbides. -an diffuse to
"l"#"nt rol" 'olatilit(
&orrosion
r"sistan&"
&ost
In&o
#)ati*ilit(
%"s&ri)tion
the base metal, resulting in
higher remelt temperature,
potentially allowing step-
bra%ing with the same alloy.
.t above &.#B worsens
corrosion resistance of nic!el
alloys. Trace amounts
present in stainless steel may
facilitate reduction of surface
chromium() oxide in
vacuum and allow fluxless
bra%ing. 9iffusion away from
the bra%e increases its remelt
temperature2 exploited in
diffusion bra%ing.",,8$
Sili&on
melting,
wetting
;i
Aowers melting point. -an
form silicides. mproves
wetting of copper-based
bra%es. 5romotes flow.
-auses intergranular
embrittlement of nic!el
alloys. @apidly diffuses into
the base metals. 9iffusion
away from the bra%e
increases its remelt
temperature2 exploited in
diffusion bra%ing.
+"r#ani!#
structural,
melting
expensive
Aowers melting point.
4xpensive. 3or special
applications. Gay create
brittle phases.
Boron
melting,
wetting
;i
Aowers melting point. -an
form hard and brittle borides.
<nsuitable for nuclear
reactors. 3ast diffusion to the
base metals. -an diffuse to
the base metal, resulting in
higher remelt temperature,
potentially allowing step-
bra%ing with the same alloy.
-an erode some base
materials or penetrate
between grain boundaries of
many heat-resistant structural
alloys, degrading their
mechanical properties. *as to
be avoided in nuclear
applications due to its
interaction with neutrons.
-auses intergranular
"l"#"nt rol" 'olatilit(
&orrosion
r"sistan&"
&ost
In&o
#)ati*ilit(
%"s&ri)tion
embrittlement of nic!el
alloys. mproves wetting
of1by some alloys, can be
added to .u-;i--r alloy to
compensate for wetting loss
by chromium addition. n
low concentrations improves
wetting and lowers melting
point of nic!el bra%es.
@apidly diffuses to base
materials, may lower their
melting point2 especially a
concern when bra%ing thin
materials. 9iffusion away
from the bra%e increases its
remelt temperature2 exploited
in diffusion bra%ing.
Mis&,#"tal
trace
additive
in amount of about &.&(B,
can be used to substitute
boron where boron would
have detrimental effects.",,8$
C"ri!#
trace
additive
in trace quantities, improves
fluidity of bra%es.
5articularly useful for alloys
of four or more components,
where the other additives
compromise flow and
spreading.
Stronti!#
trace
additive
in trace quantities, refines the
grain structure of aluminium-
based alloys.
P,os),or!s deoxidi%er
*
)
6,
6=
)
, ;i,
3e, -o
Aowers melting point.
9eoxidi%er, decomposes
copper oxide2 phosphorus-
bearing alloys can be used on
copper without flux. 9oes
not decompose %inc oxide, so
flux is needed for brass.
3orms brittle phosphides
with some metals, e.g. nic!el
(;i
'
5) and iron, phosphorus
alloys unsuitable for bra%ing
alloys bearing iron, nic!el or
cobalt in amount above 'B.
The phosphides segregate at
grain boundaries and cause
intergranular embrittlement.
(6ometimes the brittle joint
is actually desired, though.
3ragmentation grenades can
"l"#"nt rol" 'olatilit(
&orrosion
r"sistan&"
&ost
In&o
#)ati*ilit(
%"s&ri)tion
be bra%ed with phosporus
bearing alloy to produce
joints that shatter easily at
detonation.) .void in
environments with presence
of sulfur dioxide (e.g. paper
mills) and hydrogen sulfide
(e.g. sewers, or close to
volcanoes)2 the phosphorus-
rich phase rapidly corrodes in
presence of sulfur and the
joint fails. 5hosphorus can be
also present as an impurity
introduced from e.g.
electroplating baths."8$ n
low concentrations improves
wetting and lowers melting
point of nic!el bra%es.
9iffusion away from the
bra%e increases its remelt
temperature2 exploited in
diffusion bra%ing.
Lit,i!# deoxidi%er
9eoxidi%er. 4liminates the
need for flux with some
materials. Aithium oxide
formed by reaction with the
surface oxides is easily
displaced by molten bra%e
alloy.",$
Titani!#
structural,
active
Gost commonly used active
metal. 3ew percents added to
.g--u alloys facilitate
wetting of ceramics, e.g.
silicon nitride. ",$ Gost
metals, except few (namely
silver, copper and gold),
form brittle phases with
titanium. Fhen bra%ing
ceramics, li!e other active
metals, titanium reacts with
them and forms a complex
layer on their surface, which
in turn is wettable by the
silver-copper bra%e. Fets
oxides, carbides, and
graphite2 frequently a major
alloy component for high-
temperature bra%ing of such
materials."8$
Zir&oni!# structural, Fets oxides, carbides, and
"l"#"nt rol" 'olatilit(
&orrosion
r"sistan&"
&ost
In&o
#)ati*ilit(
%"s&ri)tion
active
graphite2 frequently a major
alloy component for high-
temperature bra%ing of such
materials."8$
.afni!# active
Vana%i!#
structural,
active
5romotes wetting of alumina
ceramics by gold-based
alloys.",$
S!lf!r impurity
-ompromises integrity of
nic!el alloys. -an enter the
joints from residues of
lubricants, grease or paint.
3orms brittle nic!el sulfide
(;i
'
6
)
) that segregates at
grain boundaries and cause
intergranular failure.
6ome additives and impurities act at very low levels. 7oth positive and negative
effects can be observed. 6trontium at levels of &.&#B refines grain structure of
aluminium. 7eryllium and bismuth at similar levels help disrupt the passivation
layer of aluminium oxide and promote wetting. -arbon at &.#B impairs corrosion
resistance of nic!el alloys. .luminium can embrittle mild steel at &.&&#B,
phosphorus at &.&#B.",,8$
n some cases, especially for vacuum bra%ing, high-purity metals and alloys are
used. CC.CCB and CC.CCCB purity levels are available commercially.
-are has to be ta!en to not introduce deletrious impurities from joint
contaminations or by dissolution of the base metals during bra%ing.
.lloys with larger span of solidus1liquidus temperatures tend to melt through a
ImushyI state, where the alloy is a mixture of solid and liquid material. 6ome
alloys show tendency to li/!ation, separation of the liquid from the solid portion2
for these the heating through the melting range has to be sufficiently fast to avoid
this effect. 6ome alloys show extended plastic range, when only a small portion of
the alloy is liquid and most of the material melts at the upper temperature range2
these are suitable for bridging large gaps and for forming fillets. *ighly fluid
alloys are suitable for penetrating deep into narrow gaps and for bra%ing tight
joints with narrow tolerances but are not suitable for filling larger gaps. .lloys
with wider melting range are less sensitive to non-uniform clearances.
Fhen the bra%ing temperature is suitably high, bra%ing and heat treatment can be
done in a single operation simultaneously.
4utectic alloys melt at single temperature, without mushy region. 4utectic alloys
have superior spreading2 non-eutectics in the mushy region have high viscosity and
at the same time attac! the base metal, with correspondingly lower spreading force.
3ine grain si%e gives eutectics both increased strength and increased ductility.
*ighly accurate melting temperature allows joining process to be performed only
slightly above the alloy/s melting point. =n solidifying, there is no mushy state
where the alloy appears solid but is not yet2 the chance of disturbing the joint by
manipulation in such state is reduced (assuming the alloy did not significantly
change its properties by dissolving the base metal). 4utectic behavior is especially
beneficial for solders."E$
Getals with fine grain structure before melting provide superior wetting to metals
with large grains. .lloying additives (e.g. strontium to aluminium) can be added to
refine grain structure, and the preforms or foils can be prepared by rapid
quenching. Hery rapid quenching may provide amorphous metal structure, which
possess further advantages.",$
3or successful wetting, the base metal has to be at least partially soluble in at least
one component of the bra%ing alloy. The molten alloy therefore tends to attac! the
base metal and dissolve it, slightly changing its composition in the process. The
composition change is reflected in the change of the alloy/s melting point and the
corresponding change of fluidity. 3or example, some alloys dissolve both silver
and copper2 dissolved silver lowers their melting point and increases fluidity,
copper has the opposite effect.
The melting point change can be exploited. .s the remelt temperature can be
increased by enriching the alloy with dissolved base metal, step bra%ing using the
same bra%e can be possible.
.lloys that do not significantly attac! the base metals are more suitable for bra%ing
thin sections.
;onhomogenous microstructure of the bra%e may cause non-uniform melting and
locali%ed erosions of the base metal.
Fetting of base metals can be improved by adding a suitable metal to the alloy.
Tin facilitates wetting of iron, nic!el, and many other alloys. -opper wets ferrous
metals that silver does not attac!, copper-silver alloys can therefore bra%e steels
silver alone won/t wet. ?inc improves wetting of ferrous metals, indium as well.
.luminium improves wetting of aluminium alloys. 3or wetting of ceramics,
reactive metals capable of forming chemical compounds with the ceramic (e.g.
titanium, vanadium, %irconium...) can be added to the bra%e.
9issolution of base metals can cause detrimental changes in the bra%ing alloy. 3or
example, aluminium dissolved from aluminium bron%es can embrittle the bra%e2
addition of nic!el to the bra%e can offset this.
The effect wor!s both ways2 there can be detrimental interactions between the
bra%e alloy and the base metal. 5resence of phosphorus in the bra%e alloy leads to
formation of brittle phosphides of iron and nic!el, phosphorus-containing alloys
are therefore unsuitable for bra%ing nic!el and ferrous alloys. 7oron tends to
diffuse into the base metals, especially along the grain boundaries, and may form
brittle borides. -arbon can negatively influence some steels.
-are has to be ta!en to avoid galvanic corrosion between the bra%e and the base
metal, and especially between dissimilar base metals being bra%ed together.
3ormation of brittle intermetallic compounds on the alloy interface can cause joint
failure. This is discussed more in-depth with solders.
The potentially detrimental phases may be distributed evenly through the volume
of the alloy, or be concentrated on the bra%e-base interface. . thic! layer of
interfacial intermetallics is usually considered detrimental due to its commonly low
fracture toughness and other sub-par mechanical properties. n some situations, e.g.
die attaching, it however does not matter much as silicon chips are not typically
subjected to mechanical abuse."E$
=n wetting, bra%es may liberate elements from the base metal. 3or example,
aluminium-silicon bra%e wets silicon nitride, dissociates the surface so it can react
with silicon, and liberates nitrogen, which may create voids along the joint
interface and lower its strength. Titanium-containing nic!el-gold bra%e wets silicon
nitride and reacts with its surface, forming titanium nitride and liberating silicon2
silicon then forms brittle nic!el silicides and eutectic gold-silicon phase2 the
resulting joint is wea! and melts at much lower temperature than may be expected.
"+$
Getals may diffuse from one base alloy to the other one, causing embrittlement or
corrosion. .n example is diffusion of aluminium from aluminium bron%e to a
ferrous alloy when joining these. . diffusion barrier, e.g. a copper layer (e.g. in a
trimet strip), can be used.
. sacrificial layer of a noble metal can be used on the base metal as an oxygen
barrier, preventing formation of oxides and facilitating fluxless bra%ing. 9uring
bra%ing, the noble metal layer dissolves in the filler metal. -opper or nic!el plating
of stainless steels performs the same function."#$
n bra%ing copper, a reducing atmosphere (or even a reducing flame) may react
with the oxygen residues in the metal, which are present as cuprous oxide
inclusions, and cause hydrogen embrittlement. The hydrogen present in the flame
or atmosphere at high temperature reacts with the oxide, yielding metallic copper
and water vapour, steam. The steam bubbles exert high pressure in the metal
structure, leading to crac!s and joint porosity. =xygen-free copper is not sensitive
to this effect, however the most readily available grades, e.g. electrolytic copper or
high-conductivity copper, are. The embrittled joint may then fail catastrophically
without any previous sign of deformation or deterioration.")$
ATMOSFERA DE PROTECTIE LA BRAZARE
.s the bra%ing wor! requires high temperatures, oxidation of the metal surface occurs in oxygen-
containing atmosphere. This may necessitate use of other environments than air. The commonly
used atmospheres are"E$
Air 0 6imple and economical. Gany materials susceptible to oxidation and buildup of
scale. .cid cleaning bath or mechanical cleaning can be used to remove the oxidation
after wor!. 3lux tends to be employed to counteract the oxidation, but it may wea!en the
joint.
Co#*!st"% f!"l gas (low hydrogen, .F6 type #, Iexothermic generated atmospheresI)0
(EB ;
)
, ##>#)B -=
)
, 8-#B -=, 8-#B *
)
. 3or silver, copper-phosphorus and copper-
%inc filler metals. 3or bra%ing copper and brass.
Co#*!st"% f!"l gas (decarburi%ing, .F6 type ), Iendothermic generated
atmospheresI)0 E&>E#B ;
)
, 8>+B -=
)
, C>#&B -=, #,>#8B *
)
. 3or copper, silver,
copper-phosphorus and copper-%inc filler metals. 3or bra%ing copper, brass, nic!el alloys,
Gonel, medium carbon steels.
Co#*!st"% f!"l gas (dried, .F6 type ', Iendothermic generated atmospheresI)0 E'>
E8B ;
)
, #&>##B -=, #8>#+B *
)
. 3or copper, silver, copper-phosphorus and copper-
%inc filler metals. 3or bra%ing copper, brass, low-nic!el alloys, Gonel, medium and high
carbon steels.
Co#*!st"% f!"l gas (dried, decarburi%ing, .F6 type ,)0 ,#>,8B ;
)
, #E>#CB -=, '(>
,&B *
)
. 3or copper, silver, copper-phosphorus and copper-%inc filler metals. 3or bra%ing
copper, brass, low-nic!el alloys, medium and high carbon steels.
A##onia (.F6 type 8, also called for#ing gas)0 9issociated ammonia (E8B
hydrogen, )8B nitrogen) can be used for many types of bra%ing and annealing.
nexpensive. 3or copper, silver, nic!el, copper-phosphorus and copper-%inc filler metals.
3or bra%ing copper, brass, nic!el alloys, Gonel, medium and high carbon steels and
chromium alloys.
Nitrog"n0,(%rog"n, cryogenic or purified (.F6 type +.)0 E&>CCB ;
)
, #>'&B *
)
. 3or
copper, silver, nic!el, copper-phosphorus and copper-%inc filler metals.
Nitrog"n0,(%rog"n0&ar*on #ono1i%", cryogenic or purified (.F6 type +7)0 E&>CCB
;
)
, )>)&B *
)
, #>#&B -=. 3or copper, silver, nic!el, copper-phosphorus and copper-%inc
filler metals. 3or bra%ing copper, brass, low-nic!el alloys, medium and high carbon
steels.
Nitrog"n , cryogenic or purified (.F6 type +-)0 ;on-oxidi%ing, economical. .t high
temperatures can react with some metals, e.g. certain steels, forming nitrides. 3or copper,
silver, nic!el, copper-phosphorus and copper-%inc filler metals. 3or bra%ing copper, brass,
low-nic!el alloys, Gonel, medium and high carbon steels.
.(%rog"n (.F6 type E)0 6trong deoxidi%er, highly thermally conductive. -an be used
for copper bra%ing and annealing steel. Gay cause hydrogen embrittlement to some
alloys. 3or copper, silver, nic!el, copper-phosphorus and copper-%inc filler metals. 3or
bra%ing copper, brass, nic!el alloys, Gonel, medium and high carbon steels and
chromium alloys, cobalt alloys, tungsten alloys, and carbides.
Inorgani& 'a)ors (various volatile fluorides, .F6 type ()0 6pecial purpose. -an be
mixed with atmospheres .F6 #>8 to replace flux. <sed for silver-bra%ing of brasses.
No*l" gas (usually argon, .F6 type C)0 ;on-oxidi%ing, more expensive than nitrogen.
nert. 5arts must be very clean, gas must be pure. 3or copper, silver, nic!el, copper-
phosphorus and copper-%inc filler metals. 3or bra%ing copper, brass, nic!el alloys, Gonel,
medium and high carbon steels chromium alloys, titanium, %irconium, hafnium.
No*l" gas0,(%rog"n (.F6 type C.)
Va&!!# 0 @equires evacuating the wor! chamber. 4xpensive. <nsuitable (or requires
special care) for metals with high vapor pressure, e.g. silver, %inc, phosphorus, cadmium,
and manganese. <sed for highest-quality joints, for e.g. aerospace applications.
TEHNICI DE BRAZARE
BRAZAREA CU FLACARA
Torch bra%ing is by far the most common method of mechani%ed bra%ing in use. t
is best used in small production volumes or in speciali%ed operations, and in some
countries, it accounts for a majority of the bra%ing ta!ing place. There are three
main categories of torch bra%ing in use0"E$ manual, machine, and automatic torch
bra%ing.
Manual torch brazing is a procedure where the heat is applied using a gas flame
placed on or near the joint being bra%ed. The torch can either be hand held or held
in a fixed position depending on if the operation is completely manual or has some
level of automation. Ganual bra%ing is most commonly used on small production
volumes or in applications where the part si%e or configuration ma!es other
bra%ing methods impossible."E$ The main drawbac! is the high labor cost
associated with the method as well as the operator s!ill required to obtain quality
bra%ed joints. The use of flux or self-fluxing material is required to prevent
oxidation. Torch bra%ing of copper can be done without the use of flux if it is
bra%ed with an oxygen J hydrogen gas torch set up vs. oxygen and other
flammable gasses.
Machine torch brazing is commonly used where a repetitive bra%e operation is
being carried out. This method is a mix of both automated and manual operations
with an operator often placing bra%es material, flux and jigging parts while the
machine mechanism carries out the actual bra%e."E$ The advantage of this method
is that it reduces the high labor and s!ill requirement of manual bra%ing. The use of
flux is also required for this method as there is no protective atmosphere, and it is
best suited to small to medium production volumes.
Automatic torch brazing is a method that almost eliminates the need for manual
labor in the bra%ing operation, except for loading and unloading of the machine.
The main advantages of this method are0 a high production rate, uniform bra%e
quality, and reduced operating cost. The equipment used is essentially the same as
that used for Gachine torch bra%ing, with the main difference being that the
machinery replaces the operator in the part preparation."E$
BRAZAREA IN CUPTOR
Fig2 12 S&,"#a *raz3rii in &!)tor
F!rna&" *razing is a semi-automatic process used widely in industrial bra%ing
operations due to its adaptability to mass production and use of uns!illed labor.
There are many advantages of furnace bra%ing over other heating methods that
ma!e it ideal for mass production. =ne main advantage is the ease with which it
can produce large numbers of small parts that are easily jigged or self-locating.
"#&$
The process also offers the benefits of a controlled heat cycle (allowing use of
parts that might distort under locali%ed heating) and no need for post bra%e
cleaning. -ommon atmospheres used include0 inert, reducing or vacuum
atmospheres all of which protect the part from oxidation. 6ome other advantages
include0 low unit cost when used in mass production, close temperature control,
and the ability to bra%e multiple joints at once. 3urnaces are typically heated using
either electric, gas or oil depending on the type of furnace and application.
*owever, some of the disadvantages of this method include0 high capital
equipment cost, more difficult design considerations and high power consumption.
"E$
There are four main types of furnaces used in bra%ing operations0 batch type2
continuous2 retort with controlled atmosphere2 and vacuum.
Batch type furnaces have relatively low initial equipment costs and heat each part
load separately. t is capable of being turned on and off at will which reduces
operating expenses when not in use. These furnaces are well suited to medium to
large volume production and offer a large degree of flexibility in type of parts that
can be bra%ed."E$ 4ither controlled atmospheres or flux can be used to control
oxidation and cleanliness of parts.
Continuous type furnaces are best suited to a steady flow of similar-si%ed parts
through the furnace."E$ These furnaces are often conveyor fed, allowing parts to be
moved through the hot %one at a controlled speed. t is common to use either
controlled atmosphere or pre-applied flux in continuous furnaces. n particular,
these furnaces offer the benefit of very low manual labor requirements and so are
best suited to large scale production operations.
Retort-type furnaces differ from other batch-type furnaces in that they ma!e use of
a sealed lining called a IretortI. The retort is generally sealed with either a gas!et
or is welded shut and filled completely with the desired atmosphere and then
heated externally by conventional heating elements."E$ 9ue to the high
temperatures involved, the retort is usually made of heat resistant alloys that resist
oxidation. @etort furnaces are often either used in a batch or semi-continuous
versions.
Vacuum furnaces is a relatively economical method of oxide prevention and is
most often used to bra%e materials with very stable oxides (aluminum, titanium and
%irconium) that cannot be bra%ed in atmosphere furnaces. Hacuum bra%ing is also
used heavily with refractory materials and other exotic alloy combinations unsuited
to atmosphere furnaces. 9ue to the absence of flux or a reducing atmosphere, the
part cleanliness is critical when bra%ing in a vacuum. The three main types of
vacuum furnace are0 single-wall hot retort, double-walled hot retort, and cold-wall
retort. Typical vacuum levels for bra%ing range from pressures of #.' to &.#'
pascals (#&
K)
to #&
K'
Torr) to &.&&&#' 5a (#&
K+
Torr) or lower."E$ Hacuum furnaces
are most commonly batch-type, and they are suited to medium and high production
volumes.
BRAZAREA CU ALIAE DE AR+INT
Silver brazing, sometimes !nown as a silver soldering or hard soldering, is bra%ing
using a silver alloy based filler. These silver alloys consist of many different
percentages of silver and other metals, such as copper, %inc and cadmium.
7ra%ing is widely used in the tool industry to fasten hardmetal (carbide, ceramics,
cermet, and similar) tips to tools such as saw blades. I5retinningI is often done0 the
bra%e alloy is melted onto the hard metal tip, which is placed next to the steel and
remelted. 5retinning gets around the problem that hardmetals are hard to wet.
7ra%ed hard metal joints are typically two to seven mils thic!. The bra%e alloy
joins the materials and compensates for the difference in their expansion rates. n
addition it provides a cushion between the hard carbide tip and the hard steel which
softens impact and prevents tip loss and damage, much as the suspension on a
vehicle helps prevent damage to both the tires and the vehicle. 3inally the bra%e
alloy joins the other two materials to create a composite structure, much as layers
of wood and glue create plywood.
The standard for bra%e joint strength in many industries is a joint that is stronger
than either base material, so that when under stress, one or other of the base
materials fails before the joint.
=ne special silver bra%ing method is called pinbrazing or pin brazing. t has been
developed especially for connecting cables to railway trac! or for cathodic
protection installations. The method uses a silver- and flux-containing bra%ing pin
which is melted down in the eye of a cable lug. The equipment is normally
powered from batteries.
BRAZAREA IN VID
Hacuum bra%ing is a materials joining technique that offers significant advantages0
extremely clean, superior, flux-free bra%e joints of high integrity and strength. The
process can be expensive because it must be performed inside a vacuum chamber
vessel. Temperature uniformity is maintained on the wor! piece when heating in a
vacuum, greatly reducing residual stresses due to slow heating and cooling cycles.
This, in turn, can significantly improve the thermal and mechanical properties of
the material, thus providing unique heat treatment capabilities. =ne such capability
is heat-treating or age-hardening the wor!piece while performing a metal-joining
process, all in a single furnace thermal cycle.
Hacuum bra%ing is often conducted in a furnace2 this means that several joints can
be made at once because the whole wor!piece reaches the bra%ing temperature.
The heat is transferred using radiation, as many other methods cannot be used in a
vacuum.
BRAZAREA PRIN IMERSIE
9ip bra%ing is especially suited for bra%ing aluminum because air is excluded, thus
preventing the formation of oxides. The parts to be joined are fixtured and the
bra%ing compound applied to the mating surfaces, typically in slurry form. Then
the assemblies are dipped into a bath of molten salt (typically ;a-l, L-l and other
compounds) which functions both as heat transfer medium and flux.
METODE DE INCALZIRE LA BRAZARE
There are many heating methods available to accomplish bra%ing operations. The
most important factor in choosing a heating method is achieving efficient transfer
of heat throughout the joint and doing so within the heat capacity of the individual
base metals used. The geometry of the bra%e joint is also a crucial factor to
consider, as is the rate and volume of production required. The easiest way to
categori%e bra%ing methods is to group them by heating method. *ere are some of
the most common0
"#$"+$
Torch bra%ing
3urnace bra%ing
nduction bra%ing
9ip bra%ing
@esistance bra%ing
nfrared bra%ing
7lan!et bra%ing
4lectron beam and laser bra%ing
7ra%e welding
AVANTAJE SI DEZAVANTJE
7ra%ing has many advantages over other metal-joining techniques, such as welding. 6ince
bra%ing 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. .dditionally, dissimilar
metals and non-metals (i.e. metali%ed ceramics) can be bra%ed. n general, bra%ing also produces
less thermal distortion than welding due to the uniform heating of a bra%ed piece. -omplex and
multi-part assemblies can be bra%ed cost-effectively. Felded joints must sometimes be ground
flush, a costly secondary operation that bra%ing does not require because it produces a clean
joint. .nother advantage is that the bra%ing can be coated or clad for protective purposes.
3inally, bra%ing is easily adapted to mass production and it is easy to automate because the
individual process parameters are less sensitive to variation.",, E$
=ne of the main disadvantages is0 the lac! of joint strength as compared to a welded joint due to
the softer filler metals used."#$ The strength of the bra%ed joint is li!ely to be less than that of the
base metal(s) but greater than the filler metal. .nother disadvantage is that bra%ed joints can be
damaged under high service temperatures."#$ 7ra%ed joints require a high degree of base-metal
cleanliness when done in an industrial setting. 6ome bra%ing applications require the use of
adequate fluxing agents to control cleanliness. The joint color is often different from that of the
base metal, creating an aesthetic disadvantage.
Bi*liogra),(
#. :roover, Gi!ell 5. ()&&E). Fundamentals f Modern Manufacturing! Materials
"rocesses# And Systems ()nd ed.). Mohn Filey J 6ons. 67; CE(-(#-)+8-#)++-C.
). 6chwart%, Gel G. (#C(E). Brazing. .6G nternational. 67; CE(-&-(E#E&-),+-'.
'. Aucas-Gilhaupt 6A-3=6 #( -opper16ilver15hosphorus .lloy
,. Moseph @. 9avis, .6G nternational. *andboo! -ommittee ()&&#). Copper and copper
alloys. .6G nternational. p. '##. 67; &-(E#E&-E)+-(.
8. I:uidelines for 6electing the @ight 7ra%ing .lloyI. 6ilvaloy.com. @etrieved )&#&-&E-)+.
+. "rinciples of brazing $ %oogle Boo&s. 7oo!s.google.c%. )&&8. 67; CE(-&-(E#E&-(#)-&.
@etrieved )&#&-&E-)+.
E. 'ndustrial brazing practice $ %oogle Boo&s. 7oo!s.google.com. )&&,. 67; CE(-&-(,C'-
)##)-). @etrieved )&#&-&E-)+.