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Brazing and Soldering

Book · January 2004

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Brazing and Soldering
ISBN: 964-95030-5-6

Authors: Hamid Reza Madaah Hosseini, Sharif University of Technology


Mehdi Mazar Atabaki
Ali Tahaei
Madaah Hosseini, Hamid Reza, - 1968
Brazing and Soldering/ Authors: Hamid Reza Madaah Hosseini, Mehdi Mazar Atabaki,
Ali Tahaei-
Tehran; Publisher: Entesharate Jahane Jame Jam 2004.
Pages: 220; Images, Graphs, and Table.
ISBN 964-95030-5-6
Listing according to FIPA.
1. Soldering and Brazing. A. Mazar Atabaki, Mehdi 1980-B. Tahaei, Ali 1979-J. Title.
3L4M/TS610 56/671
IRAN NATIONAL LIBRARY M82-36461

BRAZING AND SOLDEING

Authors: Hamid Reza Madaah Hosseini, Mehdi Mazar Atabaki, Ali Tahaei

Editor: Hojatollah Ali

Cover Design: Mehdi Mazar Atabaki, Ali Tahaei

Lithography: Behnoor Pardaz

Print: Negaresh

Print No.: Fourth

Number of Print: 3100

Publish Date: Winter 2004

Publisher: Entesharate Jahane Jame Jam

Address: North Janabad Street, Golzare Gharbi Street, Shahid Mohseni Baed Alley, No. 13
TEL and FAX: +98-21-4829231

Copyright reserved for publisher


Preface

Brazing and Soldering are considered as the oldest joining techniques for bonding
materials. The technical and scientific aspects of Brazing and Soldering were under scrutiny of
materials, mechanical, and chemical engineers. In many of the discovered ancient objects some
traces of Brazing and Soldering were found by archeologists. The main characteristic of this
trace was found in the traditional jewels, kitchen appliances, and packages. In recent years, many
credential references published on investigating this topic but there is not any book with a detail
and state of the art procedure to explain the theory, main parameters, machines, and overall
fundamental of the processes for variety of applications. Most of the investigations are limited to
the joining of advanced materials in electrical components while there are many opening doors
towards the application of the Brazing and Soldering processes for different industries. These
applications might cover shipyard, aerospace, automobile, electronics, advanced machines, and
many more that could potentially change the way industries making their components. This
might ameliorate environmental issues, safety, and cost efficiency of the products.

The application of Brazing and Soldering is far more than the traditional applications as
the related processes could generate precise and accurate components. The accuracy and
precision are the dominant advantageous of these processes especially in joining dissimilar
materials with complicated geometries. As there is not enough resources or at least not as much
as other welding techniques in the market, the present book has been written with the hope that
the gap in understanding of the technological, theoretical, and fundamental aspects of the
Brazing and Soldering processes could be filled. This book might be helpful for broad readership
from the professors, graduate, and undergraduate students to engineers working in wide variety
of industries.

Authors,
January 2004
Contents
Title Pages
Chapter 1 Section Joining Methods ………………………… 1
1-1 Mechanical joints ………………………… 2
1-2 Adhesive joints ………………………… 3
1-3 Welding ………………………… 4
1-3-1 Fusion welding ………………………… 4
1-3-2 Brazing and Soldering ………………………… 5
1-3-3 Solid state welding ………………………… 6
1-3-3-1 Diffusion bonding ………………………… 6
1-3-3-2 Deformation and welding ………………………… 7

Chapter 2 Fundamentals of Brazing and Soldering ………………………… 9


2-1 Comparison between Brazing and Soldering ………………………… 11
2-2 Influential parameters in Brazing and ………………………… 13
Soldering
2-2-1 Surface tension and wetting ………………………… 14
2-3 Wetting angle and capillarity effect ………………………… 16
2-4 Viscosity ………………………… 21
2-5 Process conditions ………………………… 24
2-5-1 Temperature and time ………………………… 24
2-5-2 Joint preparation ………………………… 26
2-6 Joint design and clearance ………………………… 28
2-7 Heat source and heating rate ………………………… 30

Chapter 3 Application of phase diagrams in designing ………………………… 31


Brazing and Soldering Processes
3-1 Gained information from phase diagrams in ………………………… 33
Brazing and Soldering
3-2 Dual phase diagram ………………………… 34
3-3 Ternary phase diagram ………………………… 45

3-3-1 Solid solution of eutectic filler alloys in ………………………… 45


Brazing
3-3-2 Intermetallic formation at the interface of ………………………… 48
eutectic filler alloys and substrate
3-3-3 Elemental distribution at the interface of ………………………… 54
solder filler metal and substrate
Chapter 4 Brazing and Soldering filler alloy systems ………………………… 59
4-1 Brazing filler alloys ………………………… 62
4-1-1 Pure silver ………………………… 62
4-1-2 Pure copper ………………………… 63
4-1-3 Copper-Silver eutectic ………………………… 65
4-1-4 Copper-Zinc and Zinc-Silver ………………………… 68
4-1-5 Silver-Copper-Zink ………………………… 70
4-1-6 Silver-Copper-Zink-Cadmium ………………………… 74
4-1-7 Silver-Copper-Zink-Tin ………………………… 76
4-1-8 Gold filler alloys ………………………… 77
4-1-8-1 Gold-Copper ………………………… 79
4-1-8-2 Gold-Nickel ………………………… 81
4-1-8-3 Gold-Palladium ………………………… 83
4-1-9 Palladium filler alloys ………………………… 84
4-1-10 Nickel filler alloys ………………………… 85
Contents
4-1-11 Aluminum filler alloys ………………………… 90
4-2 Soldering filler alloys ………………………… 93
4-2-1 Zink filler alloys ………………………… 93
4-2-2 Gold filler alloys ………………………… 96
4-2-3 Gold-silicone filler alloys ………………………… 97
4-2-4 Gold-Tin filler alloys ………………………… 99
4-2-5 Lead-Tin filler alloy ………………………… 101

Chapter 5 Design of Brazing and Soldering processes ………………………… 107


5-1 Brazing and Soldering atmosphere ………………………… 108
5-2 Joining flux ………………………… 115
5-2-1 Soldering flux ………………………… 117
5-2-2 Brazing flux ………………………… 122
5-2-3 Self-flux ………………………… 124
5-2-4 Ultrasonic fluxing ………………………… 124
5-3 Joint design ………………………… 125
5-3-1 Joint type ………………………… 125
5-3-1-1 Butt and lap joints ………………………… 126
5-3-1-2 Parallel and slipped butt and lap joints ………………………… 128
5-3-2 Clearance between joint components ………………………… 129

Chapter 6 Quality control and prediction of joint ………………………… 133


properties
6-1 Quality record and verification ………………………… 134
6-1-1 Brazing and Soldering characteristics ………………………… 138
6-1-2 Procedure qualification record ………………………… 139
6-1-3 Brazing qualification record ………………………… 140
6-2 Quality measurement ………………………… 144
6-2-1 Surface metallization quality ………………………… 146
6-2-1-1 Adhesive tests ………………………… 147
6-2-1-2 Surface wetting tests ………………………… 147
6-2-1-3 Tests for measuring surface uniformity ………………………… 148
6-2-2 Wetting test for filler alloy ………………………… 149
6-2-2-1 Wetting force tests ………………………… 150
6-2-2-2 Split globular test ………………………… 150
6-2-2-3 Rotary dip method tests ………………………… 151
6-2-2-4 Surface Wet-ability-spreading test ………………………… 153
6-2-2-5 Spreading area measurement ………………………… 153
6-2-2-6 Spreading test ………………………… 154
6-2-2-7 Meniscus rise end evaluation ………………………… 154
6-2-2-8 Wetting equilibrium and force measurements ………………………… 154
6-2-2-9 Suspension drop test ………………………… 158
6-2-2-10 Aging in components ………………………… 162
6-2-3 Microstructure examinations ………………………… 163
6-2-4 Mechanical properties ………………………… 169
6-2-4-1 Tensile strength test ………………………… 177
6-2-4-2 Shear test ………………………… 179
6-2-4-3 Impact, bending and peeling tests ………………………… 180
6-2-4-4 Creep test ………………………… 185
6-2-4-5 Fatigue test ………………………… 187
6-2-5 Nondestructive tests ………………………… 194
6-2-5-1 Metrological inspection ………………………… 195
6-2-5-2 Liquid penetrant test ………………………… 195
6-2-5-3 Magnetic particle test ………………………… 197
6-2-5-4 Microhardness test ………………………… 198
6-2-5-5 X-ray radiography test ………………………… 202
6-2-5-6 Ultrasonic test ………………………… 208

Bibliography ………………………… 211

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