Perform Brazing-Silver Soldering PDF

LG-MEMFAB0051A PERFORM BRAZING AND/OR SILVER SOLDERING
LEARNER’S GUIDE
PERFORM BRAZING AND/OR SILVER SOLDERING
Published by
HEART TRUST/NATIONAL TRAINING AGENCY
Produced by
Learning Management Services Department

Gordon Town Road
Kingston 7
Jamaica W.I.
This material is protected by copyright. Copying this material or any part of it by any means,
including digital or in any form is prohibited unless prior written permission is obtained from
the HEART Trust/NTA.
*** 2003***
Version 1 LRDU – AUG. 03

TABLE OF CONTENTS
PAGE
Introduction ................................................................................................................................. 1
Welcome ................................................................................................................... 1
This Competency Unit.................................................................................................... 1
Before You Start ............................................................................................................. 2
Planning Your Learning Programme ............................................................................. 2
Self-Assessment Checklist ............................................................................................. 3
How To Use This Learner’s Guide ................................................................................ 4
Using the Computer and other Resources...................................................................... 6
Method of Assessment.................................................................................................... 6
Element 1: Prepare Materials and Equipment .................................................................. 7
Self-Assessment Checklist ........................................................................................... 21
Element 2: Braze and/or Silver Solder ................................................................................ 22
Element 3: Inspect Joints ...................................................................................................... 28
Version 1 LRDU – AUG. 03

LG-MEMFAB0051A:
PERFORM BRAZING AND/OR SILVER
SOLDERING
INTRODUCTION
Welcome
Welcome to the Learner’s Guide for Unit of Competency “Perform Brazing and/or Silver
Soldering”. This is just one of a number of Learner’s Guides produced for the Skills stream of the
Metal Engineering and Maintenance Industry, and it is designed to guide you, the learner, through a
series of learning processes and activities that will enable you to achieve the specified learning
outcomes for the competency unit.
The content of this guide was developed from the Competency Standard MEMFAB0051A, which
is one of the basic building blocks for the National Vocational Qualification of Jamaica (NVQ-J)
certification within the industry. Please refer to your Learner’s Handbook for a thorough
explanation of standards and competencies, and how these relate to the NVQ-J certification.
You are also advised to consult the Competency Standard and assessment instrument for a better
understanding of what is required to master the competency.
This Competency Unit
“Perform Brazing and/or Silver Soldering” addresses the knowledge and skills requirements for
effective performance of brazing and/or silver soldering. There are three main areas or elements:
Element 1: Prepare Materials and Equipment
Element 2: Braze and/or Silver Solder
Element 3: Inspect Joints
As you go through each element, you will find critical information relating to each one. You are
advised to study them carefully so that you will be able to develop the necessary knowledge,
skills and attitudes for performing brazing and/or silver soldering.
Version 1 LRDU – AUG. 03 1

Before you start
Before you start this Learner’s Guide, you need to:
a. Obtain a Learner’s Logbook. You will use it to record evidence of your new skills/competence.
As you demonstrate your new skills, record your activities and have your learning facilitator
sign off on them. This will allow you to provide evidence of your competence when you are
being assessed against the competency standard.
b. Ensure that you have access to the facilities and equipment necessary for learning.
c. Ensure that your learning resources are available.
d. Ensure that you are wearing suitable clothing, that tools and equipment are safe, and that the
correct safety equipment is used.
e. Plan your learning programme (see below)
f. Understand how to use this Learner’s Guide (see below)
Planning your learning programme
The self-assessment checklist on the following page will assist you in planning your training
programme and it will help you to think about the knowledge and skills needed to demonstrate
competency in this unit. As you go through the checklist you will be able to find out what
elements you have already mastered and which ones you will need to pay more attention to as
you go through the learning process.
To complete the self-assessment checklist, simply read the statements and tick the ‘Yes’ or ‘No’
box. You should do this exercise now.

Self-Assessment Checklist
Perform Brazing and/or Silver Soldering
Element 1 Prepare Materials and Equipment Yes No
1. I can determine job requirements from specifications

and/or instructions ( ) ( )
2. I can prepare materials correctly using appropriate tools

and techniques ( ) ( )
3. I can assemble/align materials correctly to meet specifications

as required ( ) ( )
4. I can identify distortion prevention measures and take

appropriate action as required ( ) ( )
5. I can assemble and set up heating equipment safely and

correctly in accordance with standard operating procedures ( ) ( )
6. I can select and prepare correct and appropriate consumables ( ) ( )
7. I can undertake and verify test run as required ( ) ( )
Element 2 Braze and/or Silver Solder Yes No
1. I can select, correct and follow appropriate process to meet

specifications ( ) ( )
2. I can preheat materials as required ( ) ( )
3. I can apply consumables using correct and appropriate techniques ( ) ( )
4. I can apply jointing material correctly and in appropriate

quantities to meet job/specifications ( ) ( )
5. I can correct temperatures using appropriate techniques ( ) ( )

Element 3 Inspect Joints Yes No
1. I can remove excess jointing materials using correct and

appropriate techniques ( ) ( )
2. I can undertake inspection of joints using standard operating

procedures and meeting specifications ( ) ( )
3. I can report/record inspection results using standard operating

procedures as required ( ) ( )
How did you do?
If you ticked all or most of the ‘Yes’ boxes then you might not need to go through the entire guide.
Ask your learning facilitator to assist you in determining the most appropriate action you should
take.
If you ticked a few of the ‘Yes’ boxes or none at all then you should work through all of the guide,
even though some of the material may be familiar to you.
Plan your learning based on your answers. Be sure to involve your learning facilitator in the
planning process.
How to use this Learner’s Guide
This Learner’s Guide is designed to assist you in working and learning at your own pace.
We suggest that you:
• Go through the sections/elements as they are presented (starting at Section 1)
• Check your progress at each checkpoint to ensure that you have understood the material
• Observe the icons and special graphics used throughout this guide to remind you of what you
have to do and to enhance your learning. The icons and their meanings are as follows:

Complete Assessment Exercise

This exercise requires you to think about the knowledge and skills
that you have or will develop in this competency unit.
Definition Box
Words/phrases are defined or explained in this box. The
words/phrases being explained are in bold print.
Checkpoint
This denotes a brain teaser and is used to check your
understanding of the materials presented. No answers are
provided for the questions asked.
Activity
This denotes something for you to do either alone or with
the assistance of your trainer/supervisor.
Reference
Points you to the reference materials and other support
documents or resources used in compiling the unit content.
• Ask your learning facilitator for help if you have any problems with the interpretation of the
contents, the procedures, or the availability of resources.
• Complete each activity as you come to it. If the activity requires you perform an actual task,
be sure to tell your learning facilitator when you get to that activity so that he/she can make
any arrangements, if necessary.
• Get your learning facilitator to sign and date the Learner Logbook when you have completed an
activity.
• Complete the self-assessment checklist at the end of each section or element.
When you have worked through all elements of the guide, and when you can tick every ‘Yes’ box,
you are ready for assessment and should ask your learning facilitator to assist you in making the
arrangements to have your performance assessed.

Using the Computer and Other Resources
Where your activities refer you to the library, computer and Internet resources, ask your learning
facilitator to assist you with locating these resources. If you are getting your training in an
institution, there may be a library and a computer laboratory. If this is not the case, visit the local
library and find out what resources are available.
If you are new to the computer and the Internet, someone should be able to show you how to use
these resources.
Please note that in many of your activities you have been referred to information on the Internet.
This is because the Internet has a vast amount of information that can help you in acquiring the
particular competencies. We would like to advise you, however, that we cannot guarantee that all
the sites will be available when you need them. If this happens, ask your learning facilitator to
assist you with locating other sites that have the information you require.
Method of Assessment
Competency will be assessed while you are actually performing the tasks related to this
competency, this may be in a real workplace or a simulated situation that accurately relates to the
work situation. You are advised to consult the associated competency standard and assessment
instrument for further details relating to the assessment strategies.
You may now start your learning. Have fun while you work!

ELEMENT 1: PREPARE MATERIALS AND EQUIPMENT
LEARNING OUTCOMES
As you go through this element it will provide you with the knowledge, skills and attitudes required
to prepare materials and equipment. Your learning facilitator is there to assist you with the various
activities so on completion you should be able to:
1. Determine job requirements from work sheet specification.

2. Prepare material correctly by using appropriate tools and applying appropriate techniques.
3. Correctly assemble or align job to meet specifications based on work sheet.
4. Put all the necessary measures in place to prevent or minimize distortion.
5. Assemble and set up oxyacetylene welding equipment to complete operation.
6. Select the correct brazing rod or solder and flux to complete the job.
7. Test run the operation to ensure all steps and procedures are followed.
DETERMINE JOB REQUIREMENTS FROM WORK SHEET SPECIFICATION
As you go through this topic, you will understand that the processes of brazing and soldering are
representative of the family of metallurgical bonds.
Brazing
A metallurgical joining method using filler metal, which
melts over 425˚C and relies on wetting as well as diffusion
for the bond strength.
Soldering
A metallurgical joining method using filler metal (the solder)
with a melting point below 315˚C and relies on wetting for
the bond formation
You generally plan work from drawings or specifications or use your knowledge of fluxes and base
metals to analyze parts. You then select and set up soldering and brazing equipment and examine
joints, to ensure that they meet standards or specifications. Sometimes you may have more limited
duties or may perform routine jobs that already have been planned and laid out and do not require
extensive knowledge of soldering and brazing techniques.
Refer to: Welding, Soldering and Brazing Workers www.bls.gov/oco/ocos226.htm

Below you will see an example of a work sheet specification showing the plan and end view of mild
steel plates 1.6 mm x 38 mm x 152 mm.
38 mm
1.6mm
152mm
Material: Mild steel plate

Project: Silver solder/braze a butt joint
You should ensure that the material is correctly prepared according to specification sheet. This can
be done by:
• cutting material using hand hacksaw according to specifications

• prepare edges properly by using file or grinding machine
• using try square to check for squareness
• checking measurements to ensure they are correct
ACTIVITY
Determine job requirements from a worksheet specification

assigned to you by your learning facilitator and discuss
Solder Joint Design
The job sheet specification must be designed to bring out the major advantages of a solder joint.
In the design process you will discover that the material selection is an important aspect of the
preparation process. From the job sheet you will determine the type of base metals, the flux and
the solder alloys. There are six design qualities that you should take into consideration. They
are:
• Electrical conductivity
• Mechanical durability
• Heat dissipation
• Ease of manufacturing
• Simplicity of repair
• Visual inspectability

ACTIVITY
Discuss these six design qualities with your learning facilitator
Base Metals - The table below shows the different types of metals and their soldering capabilities:
Different types of metals and their soldering capabilities
Number Metal Solderability

1 Magnesium 2
2 Beryllium 3
3 Aluminium 2
4 Zinc 1
5 Chromium 3
6 Iron 1
7 Cadmium 1
8 Indium 1
9 Cobalt 3
10 Nickel 1
11 Tin 1
12 Lead 1
13 Hydrogen
14 Stainless Steel 2
15 Antimony 1
16 Bismuth 1
17 Silicon 3
18 Copper 1
19 Steel 1
20 Silver 1
21 Palladium 1
22 Gold 1
1 = Solders under normal conditions, 2 = Solders under special conditions,

3 = Not normally soldered

CHECKPOINT
Which one of these metals would you choose for your soldering
activity?
Flux – You must be aware that flux has two functions:
• to influence the equilibrium between the surface of the metal and the tension that exists in
the direction of the spreading solder.
• to provide surfaces that are tarnish free and to keep the surface in a clean state.
Flux
This means, “flow” in Latin. It helps in the rate and the
degree of completion of the solder joint.
There are a number of factors you should consider in the selection and use of flux:
• Time – when selecting a flux you should consider one that affect the solder quickly,
maximizing the number of joints that can be soldered per unit of time.
• Temperature – match the temperature characteristics of the flux to the assembly so that the
materials will not break down under a high temperature.
• Corrosion – this must be controlled or else the joint will weaken and eventually fail.
• Safety – the flux should give off harmless fumes during soldering.
Here are examples of fluxing materials divided into two types: inorganic and organic. Organic is
subdivided into non-rosin base and rosin base (a type of flux ingredient), which we will be looking
at:
Organic: Non – rosin base

Non- Typical fluxes Vehicle UseTemperature Tarnish Corrosiveness Post -

rosin stability removal solder
base cleaning
methods
Amines Urea, Water, Structural, Fair Good Moderate Hot water
and ethylenediamine, and electrical rinse,
amides mono and organic organic
triethanolamine solvents solvents
Resins Synthetic and Alcohols, Electrical Fair Good Slight Water and
(type natural resins organic saponifiers
SA) solvents, or
glycols terpenes;
alcohol;
organic
solvents
Organic: rosin base

Rosin Typical Vehicle Use Temperature Tarnish Corrosiveness Post-solder
base fluxes stability removal cleaning
methods
Rosin, Rosin or Alcohols, Structural, Fair Very Moderate Water base
Super resin organic electrical good detergents;
activated with solvents isopropanol;
strong organic
activators solvents
No- Rosin or Alcohols, Electrical Poor Good None Only rosins
clean resin organic can be
rosin activators solvents cleaned

PREPARE MATERIAL CORRECTLY BY USING APPROPRIATE TOOLS AND APPLYING

APPROPRIATE TECHNIQUES
As you prepare your material, there are certain steps that you should consider:
• ensure that material is properly squared up and is free from burrs by using files and try
square
• be sure the material you are soldering is completely clean. Dirt, grease or any foreign matter
limits the holding power of solder. Clean any flat surfaces, which are to be soldered with
steel wool, a file, emery cloth, etc. It's important to take time to clean the surface thoroughly
• any material to be soldered should be scraped, sanded or treated with a soldering flux before
you apply the solder
• materials should be of the correct measurement
• use the necessary soldering/brazing flux to clean metal thoroughly
remember different fluxes are recommended for different silver solders, and you should
always use the one that matches the grade you are using
File any corrosion from the top of the soldering iron or gun
There are many types of soldering pencils, guns and irons that are adequate for use. There are
soldering tips that can be used with your propane torch. There is even a small refillable butane gas-
powered soldering tool.
Before soldering with any pencil, gun or iron, be sure the tip is thoroughly cleaned. Use a light or
medium file to remove any corrosion that is built up on the tip of the soldering point. The tip of a
soldering tool should be clean at all times.
The shape of the tip on the soldering iron or gun is important. The modified chisel tip as illustrated
is ideal for most soldering jobs.

Refer to: Learning Basic Soldering:

www.nrha.org/orgill/How-To/electric/soldering/solder.htm
ACTIVITY
Prepare materials for soldering under the direction of your learning

facilitator
CORRECTLY ASSEMBLE OR ALIGN JOB TO MEET SPECIFICATION BASED ON WORK

SHEET
Soldering
There are three basic types of solder joints that you should know: sweat, which is surface to surface
(joining two flat sheets of metal, one on top of the other); strip, or edge to surface (joining a bezel to
its base); and butt, or edge to edge (joining two sheets abutting, or side by side, as in marriage of
metals or as in two wires end to end).
This simple fact dictates where the solder is placed and how the heat is applied in any solder joint.
Disregarding this principle causes more frustration and disasters than anything else except a poor fit.
Sweat-solder joint, surface-to-surface

Strip solder joint. Edge-to-edge surface
Butt solder joint. Edge-to-edge surface
• Plates should be properly squared up and free from burrs.

• Plates must be aligned according to work sheet specifications.
Brazing
Brazing is usually used to join both similar and dissimilar metals. These include:
• Steel
• Wrought and Cast Iron
• Brass
• Bronze
• Copper Alloy
• Aluminum
• Silver
The following processes are usually followed by brazing:
• Cleaning
• Filing
• Joint Preparation (for brazing, the base materials must be very clean and the joint must be
perfectly fit with each other. Thus, more time has to be spent on joint preparation.)

Below is a joint properly aligned.
Lap joint
Brazing process in progress
A strong brazing bond illustrated that is a result of proper preparation

ACTIVITY
Prepare materials for brazing or soldering as directed by your

learning facilitator and ensure to have your progress monitored
PREVENT OR MINIMIZE DISTORTION
A major concern for you, when joining, is the susceptibility to cracking and deformation. Cracks
can occur in various regions of the joint with different orientations, such as centerline cracks,
transverse cracks, and micro cracks in the underlying weld metal or adjacent heat-affected zone
(HAZ). These cracks are primarily due, to low-melting liquid phases, which allow boundaries to
separate under the thermal and shrinkage stresses during weld solidification and cooling. Types of
distortion are listed below:
• Longitudinal shrinkage
• Transverse shrinkage
• Angular distortion
• Bowing
• Buckling
• Twisting
You should ensure that distortion is prevented by:
• using a sequence of welding known as wandering that provides for making welds at
different points of the braze or solder.
• tacking welding both ends prior to completing the weld.
• supporting work piece during the soldering/brazing process.
• pre-setting parts so that welding distortion will achieve overall alignment and dimensional
control with the minimum of residual stress.
• pre-bending edges to counteract distortion and achieve alignment and dimensional control
with minimum residual stress.
ACTIVITY
Discuss with your learning facilitator the distortion prevention

methods and research other means
Refer to: Website on welding: www.weldingengineer.com/Stainless%20Steel.htm

ASSEMBLE AND SET UP OXY-ACETYLENE WELDING EQUIPMENT TO COMPLETE

OPERATION
Assembling and setting up your oxy-acetylene equipment is important for a successful operation.
The oxy-acetylene welding equipment should include:
• acetylene cylinder
• oxygen cylinder
• means of securing the cylinders in an upright position.
• acetylene and oxygen regulators and gauges
• acetylene and oxygen hoses
• welding torch
• spark lighter
• safety equipment.
Refer to: William A. Bowditch and Kevin E. Bowditch, (1997), Welding Technology
Fundamentals, The Goodyear/Willcox Company Incorporation Page 36.
Before you use the welding equipment you should:
• check to see if the cylinders are in good condition.

• fasten cylinders to hand truck to prevent them from falling.
• blow out the cylinder opening by opening the valve slightly to blow away any dirt particles
that might be there before attaching regulator to cylinder.
• inspect sealing surfaces and fittings. Avoid using worn or damage parts.
• attach regulator to cylinder. Be sure that the regulator nut fits the cylinder valve fittings
properly.
• connect hoses to regulators. Hoses should not be twisted, one around the other.
• allow high-pressure oxygen or acetylene to pass through the respective hoses, connect hoses
to torch before connecting the torch to hoses
• check for leaks. Use soapy solution on outside joints where leaks is suspected; bubbles will
indicate if any leak exists.
Oxy-acetylene equipment

ACTIVITY
With the help of your learning facilitator, assemble and set up

an oxy-acetylene welding equipment
SELECTING THE CORRECT BRAZING ROD/SOLDER AND FLUX TO COMPLETE JOB
Brazing makes use of a solder, often called spelter, which is an alloy of copper and zinc in strip,
wire or granulated form.
The brazing rod is of a special alloy that makes it possible to braze lightweight stainless steel, brass,
copper, bronze, as well as precious metals such as gold and silver.
Brazing Rods
When silver soldering you have to make use of a solder, which is an alloy of copper, zinc and
silver. An example of a silver solder is Stay Brite. This is a versatile non-toxic and low cost silver
solder of great strength for working at low temperatures. It has excellent affinity for all ferrous
and nonferrous alloys. It has more than five times the strength of ordinary tin-lead solders. It can
be used for all metals except aluminum. Stay Brite solder is a composition of 96% tin and 4%
silver and will melt at 430°C. The finished joint will be silver in color.

Solder Wire
A flux designed for external use and compatible with all of the silver solder rods offered.
Brazing flux Solder flux
ACTIVITY
Ask your learning facilitator to assist you in making the

correct selection of brazing and soldering rods and flux

TEST RUNNING THE OPERATION TO ENSURE ALL STEPS AND PROCEDURES ARE
FOLLOWED
When you are running a test, the following is to be taken into consideration:
• emery or file is used to make sure work is clean before starting

• the joint is reasonably tight
• the right flux is used
• work is packed round with firebrick to conserve heat
• the correct amount of solder is used (and size of rod) for the job
• the correct heat for solder being used must be obtained
• avoid prolonged heating. This causes scale to work into the joint
• concentrate the heat on the larger mass of the metal so that both parts of the joint are brought
together
• solder/brazing rod is dipped into flux before applying
• apply the solder at the correct time and place
• control the flow of the solder
• inspect job and make any necessary adjustment
ACTIVITY
Conduct a test run with the supervision of your learning

facilitator on prepared materials and discuss your results
CHECKPOINT
Why is it necessary to clean the joint thoroughly before

soldering?

ARE YOU READY TO PROVE YOUR COMPETENCY?
Now that you have completed this element see if you have fully grasped all the components by
doing the following self-assessment:
Checklist 1 Yes No
1. I can identify job requirements from specification sheet ( ) ( )
2. I know how to prepare material correctly by using appropriate

tools and techniques ( ) ( )
3. I know how to correctly assemble or align job to meet specifications

based on work sheet ( ) ( )
4. I understand how to put all the necessary measures in place to

prevent or minimize distortion ( ) ( )
5. I know how to assemble and set up oxy-acetylene welding

equipment ( ) ( )
6. I know how to select the correct brazing rod or solder and flux
to complete the job ( ) ( )
7. I know how to test run the operation to ensure all steps and
procedures are followed ( ) ( )
Checklist 2 Yes No
1. Job requirements from specification sheet are identified ( ) ( )
2. Material is prepared correctly using appropriate tools and

techniques ( ) ( )
3. Job is correctly assembled or aligned to meet specifications ( ) ( )
4. All necessary measures are in place to prevent or minimize

distortion ( ) ( )
5. Oxy–acetylene welding equipment are assembled and set up

appropriately ( ) ( )
6. Correct brazing rod or soldering and flux are selected ( ) ( )
7. Test run on operation was done according to procedures ( ) ( )

ELEMENT 2 BRAZE AND/OR SILVER SOLDER
LEARNING OUTCOME
As you go through this element it will provide you with the knowledge, skills and attitudes to braze
and/or silver solder. Your learning facilitator is there to assist you with the various activities, so on
completion you should be able to:
1. Select process appropriate to meet specifications

2. Preheat material as required
3. Use appropriate techniques while using consumables
4. Apply joint material correctly and in appropriate quantities to meet job specifications
5. Use correct temperature and appropriate techniques during operation
SELECT PROCESS APPROPRIATE TO MEET SPECIFICATIONS
Your selection is dependent upon:
• type of job
• desired outcome
• type of material being used
Brazing should be used for joints that are relatively strong and/or and are able to withstand
reasonable heat. Silver solder is mostly useful for brass.
Soldering is commonly used for electrical connection or mechanical joints, but brazing
is only used for mechanical joints due to the high temperatures involved.
ACTIVITY
Discuss with your learning facilitator your selection of a

joining process for the specifications that are required for
mechanical joint

PREHEAT MATERIAL AS REQUIRED
Preheating is often necessary to control or reduce the rate of expansion or contraction in a structure
during welding. This is done by preheating the entire structure before welding and maintaining the
heat during welding. When preheating be sure that you move the torch in a circular or constant
motion. Overheating should be avoided as this weakens the final joint, and is recognized by black
areas of burnt flux.
ACTIVITY
Conduct the preheating of a material for brazing or soldering

under the supervision of your learning facilitator
Use appropriate techniques while using consumables
Forehand welding technique
In this method the welding rod precedes the torch. You should hold the torch at an
approximately 30-degree angle from the vertical, in the direction of the weld. The flame is
pointed in the direction of welding and directed between the rod and the molten puddle. This
method is satisfactory for welding sheets and light plates in all positions.
Backhand welding technique
In this method, the torch precedes the welding rod. You should hold the torch at an angle
approximately 30-degrees from the vertical, away from the direction of welding, with the flame
directed at the molten puddle. The welding rod is between the flame and the molten puddle.
This position requires less transverse motion than is used in forehand welding.
Backhand welding is used principally for welding heavy sections because it permits the use of
narrower V's at the joint

Four Types of Weld Positions
Types of joints
ACTIVITY
Ask your learning facilitator to demonstrate the backhand and the

forehand methods to you, after that, try to emulate his/her example,
and then allow your work to be assessed.

APPLY JOINT MATERIAL CORRECTLY AND IN APPROPRIATE QUANTITIES TO MEET

JOB SPECIFICATIONS
Surfaces of the metals worked on for joining, should be brought to just above the melting point
of the filler rod, when the flux boils and melts into the joint. The filler rod tapped with flux
should now be touched on to the joint at the hottest part until it begins to melt and flow into the
joint. On no account should you melt the rod and allow it to drop off on the joint. The joint
should now be progressively heated and braze/silver soldered.
Welding is always done in the flat position whenever possible. The puddle is much easier to
control, and the welder can work longer periods without tiring. Quite often it is necessary to
weld in the overhead, vertical, or horizontal position in equipment repair. The flat position is
used when the material is to be laid flat or almost flat and welded on the topside. The welding
torch is pointed downward toward the work. This weld may be made by either the forehand or
backhand technique.
The overhead position is used when the material is to be welded on the underside, with the torch
pointed upward toward the work. In welding overhead, you can keep the puddle from sagging if
you do not permit it to get too large or assume the form of a large drop. The rod is used to
control the molten puddle. You should not permit the volume of flame to exceed that required to
obtain a good fusion of the base metal with the filler rod. Less heat is required in an overhead
weld because the heat naturally rises.
You should use the horizontal position when the line of the weld runs horizontal across a piece
of work, and the torch is directed at the material in a horizontal or near horizontal position. The
weld is made from right to left across the plate (for the right-hand welder). The flame is inclined
upward at an angle of 45° to 65°, and the weld is made with a normal forehand technique.
Adding the rod to the top of the puddle will prevent the molten metal from sagging to the lower
edge of the bead (the weld puddle). If the puddle is to have the greatest possible cohesion, it
should not be allowed to get too hot.
In a vertical weld, the pressure exerted by the torch flame must be relied upon to a great extent to
support the puddle. It is important that you keep the puddle from becoming too hot, and to
prevent the hot metal from running out of the puddle onto the finished weld. It may be necessary
for you to remove the flame from the puddle for an instant to prevent overheating, and then
return it to the puddle.
Vertical welds are started at the bottom, and the puddle is carried upward with a forehand
motion. The tip should be inclined from 45° to 60°, the exact angle depending upon the desired
balance between correct penetration and control of the puddle. A continual forward and
backward movement should be used. The rod is added from the top and in front of the flame
with a normal forehand technique.

CHECKPOINT
What is the importance of using a flux during soldering

operation?
What is the usual position in which welding is done? Why?
ACTIVITY
Discuss with your learning facilitator the application of the

correct quantity of joint material before trying to apply method to
successfully carry out a vertical weld
USE CORRECT TEMPERATURE AND APPROPRIATE TECHNIQUES DURING

OPERATION
The flame that you use should be neutral except when the parent or filler metal contains an
appreciable amount of zinc, in which case the flame should be sufficiently oxidizing to prevent the
zinc fuming off.
ACTIVITY
Apply method of using the correct temperature and technique on

a job specified by your learning facilitator and allow it to be
assessed.

doing the following self-assessment.
Checklist 1 Yes No
1. I know how to select appropriate processes to meet specifications ( ) ( )
2. I know how to preheat a material as required ( ) ( )
3. I understand how to use appropriate techniques while using

consumables ( ) ( )
4. I know how to apply joint material correctly and in appropriate

quantities to meet job specifications ( ) ( )
5. I know how to use correct and appropriate techniques during

operation ( ) ( )
Checklist 2 Yes No
1. Appropriate process is selected to meet specifications ( ) ( )
2. Material is preheated as required ( ) ( )
3. Appropriate techniques are used while using consumables ( ) ( )
4. Joint material is applied correctly and in appropriate quantities ( ) ( )
5. Correct and appropriate techniques are used during operation ( ) ( )

ELEMENT 3: INSPECT JOINTS
LEARNING OUTCOME
As you go through this element it will provide you with the knowledge, skills and attitudes to
inspect joints. Your learning facilitator is there to assist you with the various activities, so on
completion you should be able to:
1. Remove excess jointing materials by using appropriate techniques

2. Inspect joints by using standard operating procedures
3. Record and report inspection results
REMOVE EXCESS JOINTING MATERIALS BY USING APPROPRIATE TECHNIQUES
You can remove excess materials by:
• Grinding
• Gouging
Gouging is generally a process used for removing of weld defects. To start gouging preheat work
piece to bright red using standard blow torch with special nozzle, then remove excess material.
CHECKPOINT
What is gouging?
ACTIVITY
Discuss with your learning facilitator other methods to

remove excess materials. Do the necessary research
on the others and include grinding

INSPECT JOINTS BY USING STANDARD OPERATING PROCEDURES
A weld defect is an imperfection in the weld, which may eventually lead to failure of the soldered
joint under service conditions for which it is designed. You will perform visual inspection for
general appearance. Inspection should include:
• meeting the standard of dimensions required from drawing

• nature of penetration
• signs indicating a lack of fusion
• proper filling of joint and where possible attaining complete penetration
ACTIVITY
Inspect a job identified by your learning facilitator using the

points discussed. Record your assessment and have them
evaluated.
Refer to: For other types of inspection check pages 744 – 746 of the book Welding
Principles and Practices (1981), by Raymond Sacks, Glencoe/MacGraw-
Hill
RECORD AND REPORT INSPECTION RESULTS
Inspections are used to locate flaws and defects of the weld. Inspection results could include:
• verification of consistency of dimension of weld deposit

• uniformity of surface
• smoothness of joints
• evenly spaced ripples
• penetration
• freedom from surface imperfections.

ACTIVITY
Make a practice weld, then carry out and record inspection results.
Have your learning facilitator verify them
Refer to: Welding Principles and Practices Pages 112, 128 & 740, Sacks, Raymond
(1981), Glencoe/MacGraw-Hill

doing the following self-assessment.
Checklist 1 Yes No
1. I can explain how to remove excess jointing materials by using

appropriate techniques ( ) ( )
2. I understand how to inspect joints by using standard operating

procedures ( ) ( )
3. I know how to record and report inspection results. ( ) ( )
Checklist 2 Yes No
1. Excess jointing materials are removed using appropriate techniques ( ) ( )
2. Joints are inspected using standard operating procedures ( ) ( )
3. Inspection results are recorded and reported ( ) ( )

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LG-MEMFAB0051A PERFORM BRAZING AND/OR SILVER SOLDERING

HEART TRUST/NATIONAL TRAINING AGENCY

Learning Management Services Department

Version 1 LRDU – AUG. 03

Element 1: Prepare Materials and Equipment .................................................................. 7

Self-Assessment Checklist ........................................................................................... 21

Element 2: Braze and/or Silver Solder ................................................................................ 22

Self-Assessment Checklist ........................................................................................... 27

Element 3: Inspect Joints ...................................................................................................... 28

Self-Assessment Checklist ........................................................................................... 31

Version 1 LRDU – AUG. 03

This Competency Unit

Element 1: Prepare Materials and Equipment

Element 2: Braze and/or Silver Solder

Element 3: Inspect Joints

Version 1 LRDU – AUG. 03 1

Before you start

Before you start this Learner’s Guide, you need to:

c. Ensure that your learning resources are available.

e. Plan your learning programme (see below)

f. Understand how to use this Learner’s Guide (see below)

Planning your learning programme

Version 1 LRDU – AUG. 03 2

Element 1 Prepare Materials and Equipment Yes No

1. I can determine job requirements from specifications

2. I can prepare materials correctly using appropriate tools

3. I can assemble/align materials correctly to meet specifications

4. I can identify distortion prevention measures and take

5. I can assemble and set up heating equipment safely and

6. I can select and prepare correct and appropriate consumables ( ) ( )

7. I can undertake and verify test run as required ( ) ( )

Element 2 Braze and/or Silver Solder Yes No

1. I can select, correct and follow appropriate process to meet

2. I can preheat materials as required ( ) ( )

3. I can apply consumables using correct and appropriate techniques ( ) ( )

4. I can apply jointing material correctly and in appropriate

5. I can correct temperatures using appropriate techniques ( ) ( )

Version 1 LRDU – AUG. 03 3

Element 3 Inspect Joints Yes No

1. I can remove excess jointing materials using correct and

2. I can undertake inspection of joints using standard operating

3. I can report/record inspection results using standard operating

How did you do?

How to use this Learner’s Guide

We suggest that you:

• Go through the sections/elements as they are presented (starting at Section 1)

Version 1 LRDU – AUG. 03 4

Complete Assessment Exercise

• Complete the self-assessment checklist at the end of each section or element.

Version 1 LRDU – AUG. 03 5

Using the Computer and Other Resources

Version 1 LRDU – AUG. 03 6

ELEMENT 1: PREPARE MATERIALS AND EQUIPMENT

1. Determine job requirements from work sheet specification.

DETERMINE JOB REQUIREMENTS FROM WORK SHEET SPECIFICATION

Refer to: Welding, Soldering and Brazing Workers www.bls.gov/oco/ocos226.htm

Version 1 LRDU – AUG. 03 7

Material: Mild steel plate

• cutting material using hand hacksaw according to specifications

Determine job requirements from a worksheet specification

Solder Joint Design

Version 1 LRDU – AUG. 03 8

Discuss these six design qualities with your learning facilitator