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BrazeTec®
The Principles
of Brazing
Brazing is BrazeTec
Table of Contents
What is there to learn What is brazing? 4
Gap brazing 10
2 Brazing Content 3
What is the difference between
What is brazing? soldering and brazing?
Brazing is a thermal, material binding, joining In soldering, the melting temperature of the solder
process for metallic materials. Professional is below 450°C. In brazing, it is above.
soldering and brazing has made it possible for
every fitter to achieve a secure and guaran-
teed joint.
Brazing
above 450°C
Brazing permanently joins two or more workpieces
Melting Temperature
together by coalescence using heat with a brazing alloy
and flux. Correct application of the process ensures the
base metal is adequately wetted by the brazing alloy.
This in turn allows the brazing alloy, which is liquefied
by the heat source, to spread evenly and effectively Soldering
to firmly join the workpieces. below 450°C
!
All technical metal commodities such as copper and
Fred Flame says: copper alloys, nickel and nickel alloys, steels and ferrous
products, heavy and light metals can be brazed.
➔ Brazed joints are secure, durable and have been
well tried for generations.
Melting range
Brazing alloys usually have a melting range (also referred
to as melting interval). This melting range is limited at
Liquidus temperature Liquid brazing alloy
the bottom by the lower melting point – the solidus
temperature – and at the top by the upper melting point
– the liquidus temperature.
After reaching the solidus temperature, the brazing
alloy changes from a solid to a liquid state within the
melting range and is completely liquid when it reaches
Solidus temperature Solid brazing alloy
the liquidus temperature.
Working temperature
The working temperature is the lowest surface tempera-
ture on the parent metals to be joined at which the braz-
ing alloy moistens. This means that the brazing alloy as
well as both of the materials to be joined in the brazing
process must at least reach this temperature. The working
temperature is always higher than the solidus tempera-
ture. It can lie below or above the liquidus temperature
or fall with it.
6 Temperature Temperature 7
What is the difference
between V-joint and
gap brazing? V-joint brazing
If the surfaces of the parts to be joined have a V-joint brazing refers to brazing with a
clearance of less than 0.5 mm, we are dealing wide clearance between the workpieces.
with gap brazing. If the clearance is greater or
This method is mainly applied for design reasons or as
if the brazing joint is V or X-shaped, we call it
a result of cost and technical process considerations –
V-joint brazing. e.g. higher preparation costs – to produce a brazing joint
that fits exactly.
Gap brazing
!
8
Fred Flame says:
Gap brazing
➔ The clearance makes it a clear choice!
V-joint brazing 9
Gap brazing
The majority of all brazed joints are based Overlap joint
on the capillary joint process. The optimum The overlap joint is recommended if the workpiece brazing
clearance for a capillary joint lies between points are thin-walled. The overlapping length should
generally be 3 to 6 times the wall thickness of the thinner
0.05 mm (0.002”) and 0.2 mm (0.008”).
workpiece, depending on the base metal.
12 Tools Tools 13
4. Flux
Flux is a solvent for metal oxides. It removes oxide films
from the brazing surfaces and keeps them free of oxides
throughout the brazing process. Solders moisten, spread
5. Brazing Alloy
The following points must be taken into consideration
when selecting the correct brazing alloy for a particular
brazing task:
and bind only on clean metallic surfaces. Flux is selected
according to base metal and working temperature. Each ➔ The properties of the materials to braze
flux type has an effective temperature range. The work- (e.g. temperature sensitivity)
ing temperature of the solder to be used must lie in the ➔ The requirements for the part to be brazed
effective temperature range of the flux. when in use
(e.g. working temperature and operating pressure)
➔ The brazing procedure that is to be used
(e.g. manual brazing, machine brazing)
14 Tools Tools 15
What’s the process for
professional brazing?
Professional brazing
3.
in 7 easy steps
1.
Fixing the workpieces
The pieces to be joined must be fixed in the correct posi-
tion until the brazing alloy sets. A narrow brazing gap
of between 0.05 mm (0.002”) and 0.2 mm (0.008”) is to
Cleaning be set if possible.
Oxide layers and foreign matter such as rust and scales
must be removed from the brazing joint either mechani-
cally or chemically before brazing. Thick layers of grease
or oil can be wiped off or removed with solvents (e.g.
acetone) in the case of sensitive workpieces. Polished
workshop pieces do not require any cleaning. Any oxide
remaining on the workpiece after precleaning will be
4.
dissolved by the flux.
2.
perature so that the brazing alloy can fill the gap. The
brazing alloy selected should reach working temperature
within 3 minutes at most. Overheating will damage the
braze and the workpiece.
Applying flux
The flux paste is applied to the cold workpiece using a
brush. Most fluxes are slightly corrosive and skin contact,
particularly with wounds, should be avoided.
6.
!
Cooling
When the brazing alloy has filled the brazing gap, the
workpiece must be left to cool until the brazing alloy
returns to its solid state. The workpiece can then be Fred Flame says:
removed from the clamp and then – insofar as the mate-
rial permits – rinsed in water. ➔ A professional brazing job looks smooth and clean
and doesn’t require any touching up.
2.
the point:
Tensile Test
Take a S235 steel joint brazed with BrazeTec 4404 in a
1.
butt joint, for instance. When tested for load carrying
ability with a pulling device, the base material tears after
the test piece is loaded with 410 MPa. The three brazing
areas, however, remain untouched.
Burst pressure test
On a copper pipe fitting with five brazing joints, each
individual brazing joint is actually stronger than the base
metal. When connecting the pipe section to a high-
pressure pump, the pipe’s wall bursts at a pressure of 280
bar (4,061 psi). The brazing joints themselves withstand
the pressure and remain tight.
3.
!
Twisting test
The stability under load and distortion of a steel joint
made from S235 and brazed with BrazeTec 4404
becomes clear by turning the test piece around its own
Dr. Bob Braze says axis. A torque of 90 Nm is achieved by turning it twice.
The brazed joint withstands this load und distortion.
➔ Brazed joints are strong, durable and stay tight.
20 Stability Stability 21
What are the most commonly The details of our products and machines as well as plants and processes are based on
extensive research and experience in technical applications. We publish these results
!
BrazeTec brazing alloy BrazeTec Working BrazeTec Shear strength of the
for brazing of brazing alloy temperature in °C Flux brazed joint (MPa)
Fred Flame says:
Tungsten carbide to steel BrazeTec 4900 690 BrazeTec spezial h 250 – 300
BrazeTec 49/Cu 690 BrazeTec spezial h 150 – 300
➔ If you have any questions, just ask BrazeTec. BrazeTec 49/Cuplus 690 BrazeTec spezial h 200 – 300
www.BrazeTec.com
094-04-2006
D-63403 Hanau
Rodenbacher Chaussee 4 Tel +49 (61 81) 59 03 www.BrazeTec.com
25 www.BrazeTec.com D-63457 Hanau-Wolfgang Fax +49 (61 81) 59 31 07 info@BrazeTec.com