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The filler alloy flows into the joint by capillary attraction and this necessitates that
the clearance between the base materials in the joint region be kept very small. In
brazing the parent materials are not fused, but since the temperature is high enough
as appreciable diffusion and alloying action is possible between the brazing alloy
and the parent material. The chief feature of brazing is that many dissimilar metals
can be readily joined.
5.3 PRINCIPLE
The joint is produced by diffusion of elements of filler metal into the base metal or
vice versa. Diffusion of the elements creates bonds, which contributes to joint. Since
the filler metal is in liquid state the diffusion rate is faster than in solids. The
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capillary action plays an important role in holding the liquid filler metal which
would otherwise flow out. After soaking the samples for a long time at brazing
temperature the samples are quenched to room temperature.
The wetting angle depends upon the free surface energy of liquid-vapor interface,
solid-vapor interface and solid-liquid interface. For a good wetting the wetting
angle should be less than 90. So the free surface energy of solid-vapor interface
must be greater than solid-liquid interface. The presence of adsorbed molecules on a
metal surface markedly decreases the surface energy of solid-vapor interface and
thus increasing the contact angle. Therefore the brazing surfaces should be free from
any oxide layer or impurity. Good wetting increases the brazing efficiency.
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Application
Formulation
Comments
Oxide removal from 10 to 25% hot sulphuric Pickling can be done at same time
copper, brass, bronze, acid with 5 to 10% flux is removed. Will work on
nickel silver and other potassium
dichromate carbon steels, but if pickle is
copper
alloys added.
contaminated with copper, the
containing
high
copper will plate out on the steel and
percentages
of
will
have
to
be
removed
copper.
mechanically. This sulphuric pickle
will remove copper or cuprous oxide
stains from copper alloys. It is an
oxidizing pickle, and will discolor
the silver filler metal, leaving it a
dull gray.
Oxide removal from A 50% hydrochloric acid A mixture of 1 part hydrochloric acid
irons and steels.
solution, used cold or to 2 parts water can be used for
warm, More diluted acid Monel and other high nickel alloys.
can be used (10 to 25%) Pickling solution should be heated to
at higher temperatures about
180'F/80'C.
Mechanical
(140-160F/60-70C.) finishing is necessary for bright
finishes. This HCI pickle is not like
bright dips on nonferrous metals.
Oxide
removal 20% sulphuric acid, 20% This pickle is followed directly by a
stainless steels and hydrochloric acid, 60% 10% nitric dip, and then a clean
alloys
containing water,
used
at
a water rinse.
chromium.
temperature of 170180F(75-80C.)
20% hydrochloric acid, This pickle is more aggressive than
10% nitric acid, 70% the sulphuric-hydrochloric mixture
water, used at about listed above, and will etch both the
150F(65C.)
steel and the filler metal.
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There are many kinds of joints. But there are only two basic types the butt and the
lap. The rest are essentially modifications of these two. The butt joint, both for flat
and tubular parts:
The butt joint gives the advantage of a single thickness of the joint. Preparation of
this type of joint is usually simple, and the joint will have sufficient tensile strength
for a good many applications. However, the strength of the butt joint does have
limitations. It depends, in part, on the amount of bonding surface, and in a butt joint
the bonding area can't be any larger than the cross-section of the thinner member.
If it is compared this with the lap joint, both for flat and tubular parts
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For a given thickness of base metals, the bonding area of the lap joint can be larger
than that of the butt joint and usually is. With larger bonding areas, lap joints can
usually carry larger loads.
The lap joint gives a double thickness at the joint, but in many applications
(plumbing connections, for example) the double thickness is not objectionable. And
the lap joint is generally self-supporting during the brazing process. Resting one flat
member on the other is usually enough to maintain a uniform joint clearance. And,
in tubular joints, nesting one tube inside the other holds them in proper alignment
for brazing. However, suppose we want a joint that has the advantages of both types;
single thickness at the joint combined with maximum tensile strength. We can get
this combination by designing the joint as a butt-lap joint.
The butt-lap is usually a little more work to prepare than straight butt or lap, but one
can wind up with a single thickness joint of maximum strength. And the joint is
usually self-supporting when assembled for brazing.
5.6 ADVANTAGES
Brazing has many distinct advantages:
Economical fabrication of complex and multicomponent assemblies
Simple method to obtain extensive joint area or joint length
Joint temperature capability approaching that of base metal
Excellent stress distribution and heat transfer properties
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5.7 LIMITATIONS
A brazed joint is not a homologous body but rather is heterogeneous, composed of
different phases with differing physical and chemical properties. In the simplest
case, it consists of the base metal parts to be joined and the added filler metal.
However, partial dissolution of the base metal, combined with diffusion processes,
can change the composition and therefore the physical and chemical properties of
the boundary zone formed at the interface between base metal and filler metal.
In determining the strength of such heterogeneous joints, the simplified concepts of
elasticity and plasticity theory no longer apply. In a brazed joint formed of several
materials with different characteristics of deformation resistance and deformation
speed, the stresses caused by externally applied loads are nonuniformly distributed.
5.8 APPLICATION
Brazing gives a weaker bond than welding but brazing has its own applications. In
welding the base metal also melts and there is local casting. Welding is applicable if
both the components are of same materials. Brazing can be done for the components
of different materials and the temperature required is less than required in welding
as base metal does not melt. Brazing is widely used due to its numerous advantages.
Brazing is used in aluminum and its alloy, magnesium and its alloy, nickel alloys
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and those of copper such as brasses, bronzes, copper beryllium and the copper
silicon alloys. Among the ferrous and rarer metals the list includes carbon and low
alloy steels, stainless steel, high speed steel, cast iron, cemented carbides,
zirconium, tungsten and molybdenum.
Parameter
Soldering
Joint formed
Mechanical
Filler
metal <450
melt temp.
(C)
Brazing
Metallurgical
>450 (less than
m.p. of base
metal)
Base metal
Fluxes
Heat sources
Tendency
burn
Welding
Metallurgical
>450
(less
than or equal
to m.p. of
base metal)
Melts
Optional
Plasma;laser
Resistance;
Electron beam
Potential
distortion
the skill of the operator, the nature and working place of the parts to be brazed, the
relative costs of labor and materials. The processes are:
Torch brazing
Furnace brazing
Vacuum brazing
Dip brazing
Salt-bath brazing
Infrared brazing
Electric blanket brazing
Induction brazing
Resistance brazing
Exothermal brazing
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three sets of heater. Three sets are provided for homogeneous heating area inside the
furnace. The heater and the shields are made of molybdenum, as molybdenum is
very good reflector of heat and can bear high cyclic temperature in inert or vacuum
environment. Three vacuum pumps are attached to the furnace to give a good
vacuum. The pumps are namely: Roughening pump, Root pump, diffusion pump.
The valves attached to the furnace work with pneumatic principle. The temperatures
are reached with the help of corresponding appropriate thermocouple.
Experimental details :
The samples for vacuum brazing were made from the cold drawn OFE copper rod
having diameter 15 mm. The brazing samples had length of 40 mm. One sample of
length 80 mm was also cut for reference. The samples for brazing were turned and
made planar in C.N.C lathe. Then the samples were polished to give a perfect planar
surface. The filler metal chosen was silver copper eutectic alloy. Eutectic alloy was
used as it melts congruently and has lower melting point than copper. The samples
to be brazed were fixed in the jig made from stainless steel. Stainless steel was
chosen as it has higher melting point than both the filler and base metal and has
coefficient of linear expansion less than copper so the samples would not slip from
its position during brazing. After fixing the samples in the jig the whole combination
was put in the furnace for brazing at a high vacuum. The brazing temperature was
800 C and the soaking time was 25 min, after the soaking time the samples were
quenched with argon gas. The brazed samples and the reference were turned in
C.N.C lathe to get A.S.T.M standard tensile specimen. The tensile testing was
carried out and the different mechanical properties were obtained.
The filler metal and the base metal were also seen under microscope.
Results :
Sample
Usual OFE
cold worked
UTS
(Mpa)
359
Y.S.
(Mpa)
103
Ductility
(%)
17.6
Breaking
stress (Mpa)
57.8
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Vacuum
brazed OFE
202.23
87.07
21.4
52.3
Conclusion :
With this tensile joint design it is found that the ultimate tensile strength of
cylindrical oxygen free electrolytic copper, brazed at 800C for 25 min, is 202 Mpa
where as that of parent metal is 359Mpa. The joint efficiency of the brazed sample
at 800C is 56.33%. Investigation shows a number of plastic instability on the
brazed tensile sample compare to parent sample. Failure occurred at the brazed joint
indicating a weak region. As ductility concerns, the brazed joint exhibited 21.41%
elongation compare to that of pure copper(17.6 %).Tensile testing of brazed sample
showed a abrupt decrease in strength. This indicates there is a possibility of
improving the designed joint strength with further process optimisation.
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