Soldering and

Welding
Presented by:-
Dr. Vandana Kararia
Contents
•0 Introduction
•1 Definitions and terminologies
•2 History
•3 Soldering – components
•4 Parent metal
•5 Flux
•6 Antiflux
•7 Solder
•8 Heat source
•9 Orthodontic soldering
•10 Welding
•11 Types of welding
•12 Weld decay
•13 Clinical applications

INTRODUCTION
•14 It is often necessary to
construct many dental
appliances in two or more
parts which are later joined
together by,
•15 SOLDERING
•16 BRAZING
•17 WELDING

METAL JOINING
TERMINOLOGY
•18 SOLDERING: It is defined
as the joining of metals by the
fusion of a filler metal between
them at a temperature below the
solidus temperature of the
metals being joined and below
450°C
•19 BRAZING: It is defined as
joining of metals by the fusion of
a filler metal between them, at a
temperature below the solidus
temperature of metals being
joined and above 450°C.
•20 SOLIDUS
TEMPERATURE: the
temperature at which metals
of an alloy system become
completely solidified on
cooling or start to melt on
heating.
•21 WELDING: The joining
of two or more metal parts
by applying heat, pressure
or both, with or without a
filler metal, to produce
localized union across the
interface through fusion or
diffusion.
•22 CAST JOINING: It is the
process of combining two
components of a fixed
partial denture by means of
casting molten metal into
interlocking region between
invested components. This
is preferred for base metal
alloys because of technique
sensitivity of brazing or
soldering these alloys.
HISTORY
•23 The soldering technique
has been known to man for
ages but with the industrial
revolution in Europe as well as
North America, the need for
higher temperatures and more
user-friendly tools emerged.
•24 It was discovered that
when the vapor from heated
alcohol was ignited over a
burning wick, it burnt with a very
concentrated flame of high
temperature very suitable for
different heating purposes.
•25 Designs that emerged
using this technique were
generally called blow pipes.
The first known patent is
from France and is dated
January 7, 1791
•26 During the early
1900`s, a great variety of
blow lamps became
popular.
•27 After the Second
World War, the propane gas
emerged as a cleaner and
safer fuel for different
heating purposes.
•28 The first appliances used
had a metal frame work.
The attachment of
auxillaries to bring about the
different type of tooth
movements required
soldering of these parts.
Welding in orthodontics
became popular after the
arrival of spot welders. It
became popular because of
the short time required, the
ease of welding and the
absence of elaborate
equipments.
 SOLDERING IN
ORTHODONTICS
•29 Initially gold alloy melted
by gas torch was used to
solder gold bands.
•30 In the early 1930s
annealed stainless steel
strips were produced, and
fluoride fluxes were
introduced, enabling
successful soldering.
•31 Vosmik and taylor (1936)
, attempted to determine
soldering temperatures for
stainless steel from the
color of the wire .
•32
•33 Charles H. Tweed in
1941, gave an account on
soldering technique for steel
archwire. He noted that the
union obtained between the
steel arch wire and the
attachment by soldering is a
physical joint. Hence , he
recommended that the
solder must be flowed
around at least three sides
of the rectangular steel wire.
•34 Skinner and phillips
( 1960) gave melting range
of 607-6880C for low fusing
silver solders.
•35 It was later determined
that the temperature should
not exceed 6900C.
VARIOUS BRAZING
TECHNIQUES
•36 1 .torch brazing - heat
is applied by flame , from
some type of torch ,directly
to the base metal. A mineral
flux is normally used.
•37 2.induction brazing-
brazing temperatures are
developed in the parts to be
brazed by placing them in or
near a source of high
frequency AC electricity.
•38 3.resistance brazing
employs electrodes, which
are arranged so that the
joint forms a part of an
electric circuit. Heat is
developed by the resistance
of the parts to the flow of the
electric current .
•39 4.dip brazing , assembly
is prefluxed and dipped into
a bath of molten brazing
filler metal
•40 5.infrared brazing is a
process in which high
intensity quartz lamps are
directed on the metals to be
joined .
•41 6.furnace brazing the
parts to be brazed are
already been lightly joined
or fixed. The atmosphere
within a brazing furnace is
usually controlled, which
permits a great deal of
flexibility. An important
advantage is that potential
distortion of metal , created
by heating and cooling , can
be controlled & minimized.
•42 7.diffusion brazing,
unlike furnace brazing , is
defined not by the method
of heating but rather by the
degree of mutual filler metal
solution and diffusion with
the base metal resulting
from the temperature used
and the time interval at heat.
•43 Other techniques include
arc brazing, block brazing,
flow brazing and twin arc
brazing.
SOLDERING
•44 COMPONENTS OF
SOLDERED JOINT
•45 Parent metal
•46 Solder/filler metal
•47 Fluxes and Anti fluxes

•48 PARENT METAL

•49 The parent metal is the
metal or alloy to be joined.
This is also known as a
substrate metal or basis
meta. The composition of
parent metal determines
•50 Melting range
•51 Oxide that forms on the
surface during heating
•52 Wettability of the
substrate by the molten
solder.

•53 Soldering should take

place below the solidus
temperature of the parent
metal.
•54 The flux used should be
able to reduce the oxides,
inhibit further oxidation and
facilitate its removal.
•55 The solder chosen must
wet the metal at as low a
contact angle as possible to
ensure wetting of the joint
area.
•56 Manufacturer of the alloy
should provide guidance
and instruction regarding
the flux to be used with that
alloy.
•57 A low temp soldering is
preferred rather than the
high temp soldering for
Stainless steel wire to
prevent carbide
precipitation.
 FLUX:

•58 In Latin flux means “to

flow”. Purpose of flux is to
remove any oxide coating
on the substrate metal
surface when the filler metal
is fluid and ready to flow into
place. . The resulting
solution of oxides or other
extraneous matter in flux
constitutes “slag”.
•59 CLASSIFICATION OF
FLUX
•60 According to their
primary purpose/activity.
•61 Surface protection type:
- This type of flux covers the
metal surface and prevents
access to oxygen, so that no
oxides can form.
•62 Reducing agent type: -
This type reduces any oxides
present and exposes clean
metal.
•63 Solvent type: - This type
dissolves any oxides and
drives them away.
•64 According to their
composition
•65 Borax fluxes
•66 Fluoride fluxes
•67
•68 3. According to the pH
of the flux
•69 Acidic fluxes – SiO2
•70 Basic fluxes – CaO,
lime
•71 CaCO3 LIMESTONE
•72 Neutral – Fluorspar
(Ca.F2)
•73 Borax
(Na2B4O2)

•74 BORAX FLUXES

•75 Are used for noble
metal alloys.
•76 They are available in
•77 Liquid form: Solution of
borax/boric acid in water.
Used where minimum flux is
required.
 •78 Paste form: Formed by
mixing borax with petroleum
jelly. Required when fluxes
are needed in large quantity.
•79 Powder form: Contains a
mixture of borax, boric acid,
silica flour and finely divided
charcoal. Charcoals reducing
agent and silica holds molten
flux in surface of hot metal.
This is usually used for
casting operation.
•80

•81 FLUORIDE FLUXES:

•82 Used with base
metal alloys. The oxides
formed on base metal alloys
are more stable and
fluorides are used to
dissolve chromium, nickel
and cobalt-oxides. So it acts
as solvent.
•83 Composition:-
•84 Potassium fluoride – 50-
60%
•85 Boric acid – 25-35%
•86 Borax glass - 6-8%
•87 Potassium carbonate –
8-10%
•88 A formula for efficient flux
is
•89 Borax glass – 55
parts
•90 Boric acid – 35
parts
•91 Silica - 10 parts
•92 The ingredients may be
fused together and then
crushed to fine powder.
 APPLICATION OF
FLUX

•93 1. Painted on to the

substrate metal at the
junction of pieces to be
joined.
•94 2. Fused on to the
surface of the filler metal
strip.
•95 3. Prefluxed solders: -
solder available in a tube
form with flux contained
inside the tube.
•96 Whatever be the
technique used the most
important thing to consider
is the amount of flux used.
Too little flux tends to burn
off and will be ineffective.
Excess flux remains trapped
within filler metal and cause
a weakened joint.
•97 Flux combined with
metal oxides forms a glass
during soldering process
that is difficult to remove
completely. A two step
method for removing
residual flux is to blast joint
immediately after removal
from investment with
alumina abrasive particles
followed by boiling in water
for about 5 minutes.

ANTI FLUX
•98 Materials used to restrict
flow of solder are known as
anti flux. It is applied before
applying flux or solder.
•99 E.g.: Graphite in the form
of soft lead pencil.
•100 Disadvantage of
graphite is that it can burn
off on prolonged heating at
high temperature.
•101 In such cases rouge
or whiting (CaCO3 in alcohol
and water suspension) is
used.
 FILLER
METAL/SOLDER

•102 Qualities of an ideal

solder
•103 Ease of flow at
relatively low temperature.
•104 Sufficient fluidity to
freely flow when melted.
•105 Ability to wet substrate
metal.
•106 Strength compatible
with that of the structure
being joined.
•107 Resistance to tarnish
and corrosion.
•108 Acceptable color to
give an inconspicuous joint.
•109 Resistance to pitting
during heating.
FLOW
TEMPERATURE

•110 The temperature at

which the filler metal wets
and flows on the substrate
metal and produces a bond.
It is usually higher than the
liquidus temperature.
•111 ISO 9333 requires
that the flow temperature of
the filler metal should be
lower than the solidus
temperature of the substrate
metals. A rule of thumb is
that flow temperature of the
filler metal should be 55.6°C
(100°F) lower than the
solidus temperature of the
substrate metal.
•112 If the flow point of
the filler metal is close to or
above the solidus of either
substrate alloying can take
place. An alloy formed
through diffusion can have
properties different from
filler metal and substrate
metal.

CLASSIFICATION
OF SOLDERS

•113 I. Soft solders

•114 Hard solders
•115
•116 II. Precious metal
solders
•117 Non precious
metal solders

•118 SOFT SOLDERS

lead- tin eutectic alloy with a
low melting point
Sometimes called as
plumbers solder.
They have low fusion range
of about 260°C or less.
Soft solders lack corrosion
resistance

•119 HARD SOLDERS

•120 Hard solders have
higher meting temperature
& possess greater hardness
and strength.
•121 Heating is done with
gas torch or special devices.
•122 Two types of hard
solders are used in
dentistry.
•123 Gold solders
•124 Has good tarnish and
corrosion resistance
•125 Extensively used for
crown and bridge
applications.

•126 Composition -
•127 Gold – 45-81 wt %
•128 Silver- 8-30 wt %
•129 Copper-7-20 wt %

with small amounts of Tin,

Zinc and Phosphorus to
modify fusion temperature
and flow qualities.
•130 They are high fusing
with a fusion temperature
range of 750- 900° C.

•131 Silver solders

•132 Used in orthodontic
appliances
•133 They are low fusing –
fusion temp-600-750°C
•134 Used with stainless
steel or other base metal
alloys
•135 Resistance to tarnish
and corrosion is not as good
as gold solders
•136 But have strength
comparable to gold solders
•137
•138 Composition
•139 Silver -10-80
%
•140 Copper -15-
30%
•141 Zinc -4-35%,
with small amounts of
cadmium, tin and
phosphorus.
•142 The formation
of silver-copper eutectic is
responsible for the low
melting range of silver
solder.

Basis of selecting
solders
•143 Ease of flow at
relatively low temperature
•144 Sufficient fluidity to
freely flow when melted
•145 Strength compatible
with that of the structure
being soldered
•146 Acceptable color to
give an inconspicuous joint
•147 Resistance to tarnish
and corrosion
•148 Resistance to pitting
during heating and
application

HEAT SOURCE
•149 The most common
instrument used as heat
source is gas- air or gas-
oxygen torch. The type of
torch depends on the type
of fuel.
•150 The fuels used are
•151 Hydrogen-low heat
content, so heating is slow.
•152 Natural gas- heat
content is four times that of
hydrogen.
•153 Acetylene- high flame
temperature, but variation in
temperature from one part
of the flame to the other part
is more than 100°C. So
positioning of the torch is
critical. It is chemically
unstable gas, decompose to
carbon and hydrogen.
Carbon can get
incorporated in to nickel and
palladium alloys.
•154 Propane- is the best
choice. Have highest heat
content& good flame
temperature.
•155 Butane- has similar
flame temperature and heat
content. Both are readily
available. Uniform in quality,
virtually water free and burn
clean.

FLAME

•156 The flame can be

divided in to four zones
•157 cold mixing zone
(unburned gas)
•158 partial combustion
zone (oxidizing)
•159 reducing zone
•160 oxidizing zone
(burned gas)
•161 Improperly adjusted
torch or improperly
positioned flame can lead to
oxidation of the substrate or
filler metal and result in a
poorly soldered joint.
•162 If unburned portion of
flame is used carbon may
be introduced to the
substrate or filler metal.
•163 To prevent oxide
formation the flame should
not be removed once it has
been applied to the joint
area until soldering process
has been completed.
OVEN (FURNACE)
SOLDERING

•164 A furnace with enough

wattage to provide heat
required to raise the
temperature of the filler
metal to its flow point.
•165 Advantages:
•166 Uniform temperature
•167 Close monitoring is
possible
•168 Temperature is known
•169 Application of vacuum
control oxidation

INFRARED
SOLDERING
•170 The unit uses light
from a 1000 watt Tungsten
filament, quartz- iodine bulb
which is mounted at the
primary focal point of a gold
plated elliptical reflector.
The material to be soldered
is placed at the reflectors
secondary focal point at
which the reflected infrared
energy of Tg light source is
focused. This is used for
high temperature soldering.
 TECHNIQUES OF
SOLDERING

•171 Investment soldering

•172 Free hand soldering

INVESTMENT
SOLDERING
•173 Used when very
accurate alignment of parts
to be joined is needed. The
parts are placed on the
master cast with a gap of at
least 1mm. the parts are
fastened with sticky wax
before placing soldering
investment. Anti flux is
applied to confine the flow
of solder.
•174 The investment is
preheated to eliminate
moisture. Flux can be
applied before or after heat
treatment. Soldering is
carried out with reducing
flame at 750- 870°C. The
investment is cooled 5 min
before quenching. Flux will
cool to a glass which is
removed by pickling.

FREE HAND
SOLDERING
•175
•176 Free hand soldering
is used for soldering
orthodontic appliances.
Orthodontic torches can be
placed on a bench so that
both hands can be used to
hold the parts in position.
•177 SOLDER JOINT GAP
•178 If the gap is too great
the strength will be
controlled by the strength of
the filler. If the gap is narrow
the strength will be limited
by the flux inclusions &
porosities by the incomplete
flow of the filler, metal.

MINI TORCH

•179 The maximum

temperature it can produce
13000C.
•180 Ignition & flame
adjustment is easy.
•181 Adjustable nozzle
•182 Refill is easy with a
capacity of 30ml.
SOLDERING CLAMP

•183 It has dual arms for

freehand soldering.
•184 Easily movable in all
directions.
•185 Pointed holder with
claws.
 HYDROSOLDEER
UNIT

•186 Adjustable gas

production with indicator
lamp.
•187 Indicator for gas
pressure, mains, reservoir
level and electrolyte maybe
present.
•188 It has a safety
pressure switch.
•189 Uses hydrogen as
fuel.
•190 The gas is released
through very fine nozzle to
provide concentrated flame.
STEPS IN
SOLDERING

•191 Cleaning and

preparing the surfaces to be
joined
•192 Assembling the parts
to be joined
•193 Preparation and
fluxing of the gap surfaces
between the gaps
•194 Maintaining the proper
position of the parts during
procedure.
•195 Control of proper
temperature
•196 Control of time to
ensure adequate flow of the
solder& complete filling of
the solder joint
Laser brazing
•197 Laser can deliver very
low to extremely high
focused power with a
precise spot size /dimension
and interaction /pulse time
( 10-3 to 10-15s ) on to any
kind of substrate through
any medium . Laser is
distinguished from other
electromagnetic radiation
mainly in terms of its
coherence, spectral purity
and ability to propagate in a
straight line .
 ORTHODONTIC
SOLDERING

•198 In orthodontic
applications low
temperature soldering is
used to prevent carbide
precipitation and to prevent
excessive softening of the
wire. Low fusing silver
solders are used with a
soldering temperature range
of 620-655°C. Fluoride
fluxes are used for
orthodontic stainless steel
and other base metal alloys.
•199 Free hand soldering
technique is employed with
a needle like non luminous
gas air flame is used. The
work should be held 3mm
beyond the tip of the blue
cone in the reducing zone of
the flame. Soldering should
be observed in a shadow,
against a black back
ground, so that the
temperature can be judged
by the color of the work. The
color should never exceed a
dull red.
•200 Flux must cover all the
areas to be joined before
heat is applied. As soon as
the flux fuses solder is
added and heating is
continued until metal flows
around the joint. The work
is then removed from the
heat and quenched in water.
•201 Hydrogen-Oxygen
torch, electric resistance
heating & indirect heating
with brass wire intermediary
are also used as heat
source
 SOLDERING
APPLICATIONS IN
ORTHODONTICS

•202 Wire to wire

•203 Tubes can be
soldered to the bridge of the
Adams clasp. Here the
arrow heads, tags, and base
plate are protected with
damp paper.
•204 Attachment of springs
to arch wire. When
soldering an auxiliary spring
to arch wire, the solder must
be a gold one with a melting
point below 800°C.

•205 The components are

cleaned & scraped.
•206 Fluoride flux is applied
•207 Solder is made to flow
to form a bead & then the
wire is polished with a
pumice stick.
•208 Spring is attached
obliquely & then twisted.
•209 It should not be
0
heated more than 800 C
else it will lose its
mechanical properties.
( Mershon technique).
•210 Soldering lingual arch
or palatal arch: to hold the
arch during soldering
position it on the model and
place a blob of wet pumice
over the middle portion of
the model. Water is
immediately soaked on to
the cast leaving dried
pumice which is firm enough
to secure the arch during
soldering.
•211 The lock wire is
attached to the end of the
arch wire by means of gold
solder
 SOLDERING
FAILURES

•212 Are due to:

•213 Failure to clean the
parts to be joined.
•214 Improper fluxing
•215 Poor flow of solder
•216 Over heating of the
solder can lead to pitted
joint of low strength
 CORROSION OF
SOLDERED JOINTS
•217 material containing up
to about 20 percent zinc and
20 to 30 percent copper with
low cadmium and tin cannot
remain inactive to
physiologic solutions. Weak
corrosion-prone micro
structural phases composed
mainly of copper and zinc
occur within the solder itself.
It is known that corrosion
occurs when an electrolyte
comes into contact with a
soldered joint.
•218 The silver solders
react readily to chemical
attack. The breakdown
reaction between silver-
soldered stainless steel
joints is an electrochemical
process with no initial
evidence of gross
macroscopic corrosion. After
a time, many silver-soldered
joints exhibit a change in
appearance such as
darkening to resemble a
tarnished, corroded surface.
BIOCOMPATIBILITY

•219 Laboratory tests

indicate that silver-soldered
stainless steel joints
degrade in a saliva
substitute and other
prepared solutions.
Corrosion products
containing oxides,
hydroxides, and chlorides of
zinc, copper, tin, and
cadmium can be easily
identified. Silver is also
attacked.
•220 Besides the oral
physiologic fluids, additional
chemical agents contained
in mouth rinses and in
toothpastes for oral
antiseptic, antimicrobial,
antiplaque, and anticaries
purposes need careful
appraisal for resistance to
the degradation and
corrosion of dental
materials. Many commercial
mouth rinses contain active
chlorides and additional
components. The chlorides
are notorious for their
 depassivation tendencies of
metallic materials.

NEWER SILVER
SOLDERS
•221 The newer alloys have
10% tin for wetting stainless
alloys.
•222 3% nickel for crevice
corrosion immunity.
•223 Cadmium & zinc have
been eliminated.
•224 Melting range 700 to
0
900 C.
•225 BAg18 & Bag 21
(American welding society)
WELDING

•226 Welding is the process

by which the surfaces of
metals are joined by mixing,
with or without the use of
heat.
•227 Cold welding is done
by hammering or pressure.
An example of cold welding
is the gold foil filling.
•228 Hot welding uses
heat of sufficient intensity to
melt the metals being
joined. The heat source is
usually an oxyacetylene
flame or high amperage
electricity.
TYPES OF
WELDING

•229 Spot welding

•230 Pressure welding
•231 Laser welding
•232 plasma welding
 THEORY

•233 Orthodontic spot

welders employ the
electrode technique and are
used instead of soldering in
cases where the heating
cycle must be very short, in
order to prevent changes in
the physical properties of
the components being
joined.
•234 Orthodontic welding
is achieved by passing a
large amount of current for a
very short duration through
an area of high resistance.
Heat is generated of a
magnitude great enough to
cause melting at the
interface.
•235 Copper electrode -
Low resistance
•236 Stainless steel - 50
times higher resistance than
that of copper.
•237 Electrode – Stainless
steel inter face: 2 times of
S.S alone.
•238 Stainless steel –
Stainless steel interface : 4
times of S.S alone.
•239 Thus, in orthodontic
welding, the resistance at
the junction between the
two pieces of stainless steel
being joined is much greater
than that of either the
electrode or the stainless
steel masses. Because of
this differential resistance,
essentially all of the heat
generated by the current
flow is contained within the
weld area.
•240 As sufficient heat is
generated at the weldmate-
weldmate interface, the
stainless steel components
soften, flow and fuse
together under the influence
of mechanical pressure,
forming a weld nugget.

•241 In spot welding the

following three properties of
the metal are favorable:
•242 A comparatively low
melting point (approximately
1370° C.),
•243 high electric
resistance,
•244 And low conductivity
of heat.

•245 The welding is done

mechanically by gripping the
seam between two snub-
nosed welding dies
(electrodes) made of
hardened copper, and
passing low voltage high
amperage current.
•246 In any welding
operation it is important to
minimize the area heated
and to shorten the time of
passing the current through
the metal. Since the
complete separation or
formation of the carbide
phase does not occur
instantaneously the
maximum effect is obtained
only with prolonged heating.
•247 Heat developed is
2
directly proportional to I RT
where,
•248 I - The current
•249 R - The resistance
•250 T - Time of
application

•251 The volume of metal

to be heated is definite for a
given thickness of metal and
the current and time must
be controlled accurately.
•252 It is easy to weld
two sheets of metal of the
same thickness, but the
welding of sheets of
markedly different thickness,
or wire to wire or a tube to a
sheet, is extremely difficult
and therefore should be
avoided. In such cases
some orthodontists
recommend the use of a
special form of electrodes,
but whether the results are
truly favorable is somewhat
doubtful.
 Electric circuit of a
spot welder

VARIABLES AND
THEIR
MISAPPLICATION
•253 1. The current flowing
through the circuit.
•254 2. The time during
which the current is allowed
to flow.
•255 3. The mechanical
pressure applied at the
welding head.
•256 The improper
application of these
variables can result in either
over- or under welding of
the weldmate.

•257 An under welded

assembly
•258 - Insufficient
current;
•259 - The current
passed for an insufficient
amount of time
•260 - Pressure applied
inadequate in
approximation.
•261 Over welding
- yield weak a joint as under
welding.
- Progressive corrosion. This
occurs when chromium is
precipitated at the grain
boundaries of each crystal.
This process is known as
weld decay.
•262 A satisfactory welded
joint is one which is strong,
has not undergone oxidation
(blackening), and has not
been over compressed
during fusion.

NEW ELECTRODES FOR

WELDING
ORTHODONTIC WIRES
TMS ELECTRODE (DR.
HEINZ WINSAUER)
•263 The TMS electrodes
(the abbreviation is for
Titanium Molybdenum and
Steel wires) are made of
space-age materials and
coated with a chemical
agent that both protects the
electrodes and assures
smooth, parallel surfaces.
•264 The coating lasts for
as many as 1000 welds.
The electrodes can be used
in any common welder,
whether in capacitor or
transformer mode.
•265 The TMS electrode
can be used with any
orthodontic wires, including
stainless steel, titanium
molybdenum, and
multistranded, without
bowing of the wires. It works
with a wide range of
pressure and voltage; in
most cases, wires for fixed
appliance treatment can be
welded with a constant
voltage setting.
 CLINICAL
APPLICATION

•266 1.The weldmates

should be clean of all
extraneous materials and
oxides.
•267 2. The surface of
each electrode must be
smooth, flat, and
perpendicular to its long
axis. When the electrodes
are together, they should be
in total
contact. If not, they should
be filed until total contact is
achieved. Sparking and
localized over welding will
result if interface contact is
not uniform.
•268 3. Adjust the welder
to settings recommended by
the manufacturer.
•269 4. Select the proper
electrode for the thickness
or shape of the material to
be welded.
•270 Insert the weldmates
between the electrodes,
close them together, and
depress the weld button.
•271 If sparking is
observed, localized over
welding has occurred

TECHNICAL
CONSTRUCTION OF
APPLIANCES
•272 To make an incisor or
a molar band, it is
necessary to have them
overlap less than 1 mm.
•273 the overall depth of
fusion should not be less
than 50 per cent of the
combined thickness of the
two sheets, or more than 80
per cent. A good way to test
welds is to twist them apart.
If the weld fails by rotational
shear at an angle less than
70° the fusion has been too
shallow.
•274 Spot welding is used
when uniting a band with a
band or a band with flange;
otherwise soldering is
considered more advisable.

WELDING OF TMA
WIRE
•275 Beta titanium (TMA)
wire can be directly welded
without solder, producing
joints that have high
springback and strength. As
the only orthodontic wire
with this capability, TMA
offers the potential for many
applications during
treatment, particularly where
welding is required for
active tooth movement.
 Principles of TMA
welding
•276 POSITIONING- Broad,
flat electrodes are used and
wires are held in tight
contact.
•277 When the current is
applied through the two
wires, a melting process
occurs. This is not just a
surface weld, but an actual
merging in which one wire
has "set down" about 80%
into the second wire. The
concept of "set down" is
important in evaluating the
success of welds. A 25-60%
"set down" is recommended
for most applications.
•278 VOLTAGE-Greater
voltages leading to
increased heat may lead to
increased wire brittleness;
however, springback
properties would not be
affected.
•279 CONTACT AREA-
Smaller contact areas
between parts are desirable
because higher localized
heats are produced, giving
an excellent weld without
influencing the remainder of
the wire.
•280 PULSE- It is important
that the basic weld be
accomplished with only one
pulse, and that the pulse is
of very short duration.
•281IMPROPER
WELDING
•282 Improper welding can
occur at the two extremes.
•283 Too low voltage --
parts may delaminate.
•284 Too high voltage -- the
wire can become brittle.
•285 OVERHEATING THE
WIRES.
•286 100% "set down" in
the main archwire.
•287 - Cracks are formed
around the hook as the wire
cooled.
•288 - This could
lead to fracture if the
archwire is bent
•289 - recommend
"set down" is typically less
than 60%.
A CHECKLIST FOR
SUCCESSFUL
WELDING:

•290 Mount the electrodes

correctly in the welder and
adjust with parallel,
precision filing to eliminate
gaps.
•291 Weld together only
wires of the same material.
•292 Place the thinner wire
in the groove of the lower
electrode.
•293 Decrease the contact
resistance of the wires with
one or two 90° scissor-like
movements while applying
pressure with the
electrodes.
•294 Use 1540 Newtons of
pressure.
•295 Set the voltage
according to the operating
instructions.
•296 Use a single electrical
impulse.
 THANK
YOU