PSG College of Technology, Coimbatore

Department of Production Engineering

19P305 Welding Technology
BE Production Engineering
Semester – 3 (AY 2020-2021)

Soldering and Brazing

Mr.K.Saravanakumar
Assistant Professor (Senior Grade)
Department of Production Engineering
PSG College of Technology
Coimbatore – 641004
Contents
✓ Soldering
✓ Types of soldering fluxes
✓ Soldering Methods
✓ Soldering Procedure
✓ Safety precautions in soldering
✓ Soldering defects and remedies
✓ Brazing
✓ Brazing Methods
✓ Difference between welding, soldering and brazing
Soldering
Soldering is a method of joining two metal work pieces by means of a third metal
(solder) at a relatively low temperature, which is above the melting point of the solder
but below the melting point of either of the materials being joined.
Solder – filler metal
✓ Alloys of Tin (silver, bismuth, lead)
✓ Melt point typically below 840 degree F
Flux used to clean joint & prevent oxidation
✓ Separate or in core of wire (rosin-core)
Tinning = pre-coating with thin layer of solder
Applications:
✓ Printed Circuit Board (PCB) manufacture
✓ Pipe joining (copper pipe)
✓ Jewelry manufacture
✓ Typically non-load bearing
Easy to solder: copper, silver, gold
Difficult to solder: aluminum, stainless steels
 Soldering
✓ Flow of the molten solder into the gap between the work pieces is driven by the
capillary force.
✓ The solder cools down and solidifies forming a joint.
✓ The parent materials are not fused in the process.
✓ Soldering is similar to brazing. The difference is in the melting point of the filler
alloy: solders melt at temperatures below 840°F (450°C); brazing filler materials
melt at temperatures above this point.
✓ The difference between soldering and welding processes is more sufficient: in the
welding processes edges of the work pieces are either fused (with or without a
filler metal) or pressed to each other without any filler material; soldering joins
two parts without melting them but through a soft low melting point solder.
✓ Soldering joints have relatively low tensile strength of about 10000 psi (70 MPa).
 PCB Soldering PTH - Pin-Through-Hole connectors
Manual PCB Soldering

Soldering Iron & Solder Wire

Heating lead & placing solder

Heat for 2-3 sec. & place wire

opposite iron

Trim excess lead

PCB reflow soldering – Automated reflow soldering
SMT = Surface Mount Technology
✓ Solder/Flux paste mixture applied to PCB using screen print or similar transfer method.
✓ Solder Paste serves the following functions:
✓ supply solder material to the soldering spot,
✓ hold the components in place prior to soldering,
✓ clean the solder lands and component leads
✓ prevent further oxidation of the solder lands .
Printed solder paste on a printed circuit board (PCB)

✓ PCB assembly then heated in “Reflow” oven to melt solder and secure connection
TYPES OF SOLDERING FLUXES
Soldering fluxes can be classified as :
(a) Organic, and
(b) Inorganic fluxes.
Organic Fluxes
✓ Organic fluxes are either rosin or water soluble materials.
✓ Rosin used for fluxes are wood gum, and other rosin which are not water
soluble.
✓ Organic fluxes are mostly used for electrical and electronic circuit making.
✓ These are chemically unstable at elevated temperature but non-corrosive at
room temperature.
Inorganic Fluxes
✓ Inorganic fluxes are consists of inorganic acids; mixture of metal chlorides
(zinc and ammonium chlorides).
✓ These are used to achieve rapid and active fluxing where formation of oxide
films are problems.
Fluxes should be removed after soldering either by washing with water or by
chemical solvents.
The main functions performed by fluxes are
(a) remove oxide films and tarnish from base part surfaces,
(b) prevent oxidation during heating, and
(c) promote wetting of the faying surfaces.
The fluxes should
(a) be molten at soldering temperature,
(b) be readily displaced by the molten solder during the process, and
(c) leave a residue that is non-corrosive and non-conductive.
Soldering methods
Hand soldering
✓ Iron soldering utilizes a heat generated by a soldering iron.
✓ Torch soldering utilizes a heat of the flame from a torch.
✓ The torch mixes a fuel gas with oxygen or air in the proper ratio and flow
rate, providing combustion process at a required temperature.
✓ The torch flame is directed to the work pieces with a flux applied on their
surfaces.
✓ When the work pieces are heated to a required temperature, solder is fed
into the joint region.
✓ The solder melts and flows to the gap between the joined parts.
✓ Hand soldering is used in repair works and for low volume production.
Wave soldering
✓ The method uses a tank full of a molten solder.
✓ The solder is pumped, and its flow forms a wave of a predetermined height.
✓ The printed circuit boards pass over the wave touching it with their lower sides.
✓ The method is used for soldering through-hole components on printed circuit
boards.
Reflow soldering
✓ In this method a solder paste (a mix of solder and flux particles) is applied onto
the surface of the parts to be joined and then are heated to a temperature
above the melting point of the solder.
✓ The process is conducted in a continuous furnace, having different zones:
preheating, soaking, reflow and cooling.
✓ The joint forms when the solder cools down and solidifies in the cooling zone of
the furnace.
Soldering Procedure
1.Work Preparation
✓ Workpieces which are to be joined together should be perfectly clean.
✓ There should not be any dirt, dust, rust, paint or grease.
✓ This is so that the solder or spelter can stick to the joint with proper
strength.
✓ Cleaning is done with the help of a file or sandpaper.
✓ In case of joining of conducting wires, insulation of portion to be joined
should be perfectly removed.
✓ Sometimes chemicals are used to clean the workpieces.
✓ De-scaling (removal of scaling) is done by dipping the workpieces into dilute
HCl.
2.Preparation of Joint
✓ After cleaning workpieces should be kept together in correct position to make
the final joint.
✓ Workpieces should be clamped to avoid any relative movement between them
that may disturb the joint making.
✓ At the joint smaller grooves are made on the workpieces to facilitate better
flow of molten solder and so good strength of the joint.
✓ There may be the two objectives of joint :
✓ to bear load, and
✓ to make electrical contact.
✓ In case of load bearing joints lap joint or butt joints are preferred.
✓ It is important to note down that strength of a soldered joint can not be
compared with welded joint.
✓ If electrical contact is to be made the solder should be so selected that
resistance of joint should match with the resistance of the conductor.
3.Fluxing
✓ Fluxing includes selection of appropriate flux and its application to the joint.
✓ Selection of flux depends on the material of workpiece keeping its purpose in view.
✓ It is applied to the joint with the help of a Soldering and Brazing brush before
soldering.
✓ It avoids oxidation of molten metal, helps in flow of molten solder into the joint
and so maintains strength of the joint.
4.Tinning
✓ In this step of soldering procedure, the bit of solder iron is cleaned, application of
flux is done over it.
✓ It is brought in contact of solder wire so the bit carries sufficient amount of molten
solder over it.
✓ After that it is used to make tags of solder at various process through out the joint.
✓ If soldering is done to make electrical contacts of conductivity wires the complete
joint is made by tagging few times.
✓ In case of long joint, after tagging the molten solder is filled to the joint by
bringing hot bit of solder iron and solder wire together in contact with the joint.
✓ Filling the joint with molten solder and allowing to solidify is the last step of the
procedure called soldering
Soldering defects and remedies

Some of the common soldering defects are:

✓ (a) Granular formation at the surface of the joint of solder is one of the
common soldering defects.
✓ (b) Formation of spheroids at the surface of soldering joint is also similar
defect. This happen due to under heating or over heating of solder iron,
insufficient use of flux. Formation of spheroids make the joint ugly and week
in strength.
✓ (c) Improper or uneven application of flux may make the joint of weaker
strength.
✓ (d) Proper coordination between flux application and soldering makes the
joint of good quality.
Safety precautions in soldering
(a) Keep solder iron always on its stand.
(b) All electrically operated instruments/equipment should have proper earthing.
(c) Sometimes emission of (smoke) soldering operation may be poisonous due to a
particular type of flux. Operator should have protection from the same.
(d) Flux should be applied gradually while soldering.
(e) While diluting HCl, water should not be added to HCl but HCl should be mixed
into the water drop by drop, to avoid accident.
(f) Work place should have enough ventilation and smoking should be strictly
prohibited during the operation. Work place should have the facility of first aid.
(g) It should be noted down good quality surface preparation always contributes
to good quality joint.
Brazing
✓ Use of low melt point filler metal to fill thin gap between mating surfaces to be
joined utilizing capillary action
✓ Filler metals include Al, Mg & Cu alloys (melt point typically above 840 degree
F)
✓ Flux also used
✓ Applications:
✓ Automotive - joining tubes
✓ Pipe/Tubing joining (HVAC)
✓ Electrical equipment - joining wires
✓ Jewelry Making
✓ Joint can possess significant strength
Brazing
Brazing is a method of joining two metal work pieces by means of a filler material at a
temperature above its melting point but below the melting point of either of the
materials being joined.
✓ Flow of the molten filler material into the gap between the work pieces is driven by
the capillary force.
✓ The filler material cools down and solidifies forming a strong metallurgical joint,
which is usually stronger than the parent (work piece) materials.
✓ The parent materials are not fused in the process.
✓ Brazing is similar to Soldering.
✓ The difference is in the melting point of the filler alloy: brazing filler materials melt
at temperatures above 840°F (450°C); soldering filler materials (solders) melt at
temperatures below this point.
✓ The difference between brazing and welding processes is more sufficient: in the
welding processes edges of the work pieces are either fused (with or without a filler
metal) or pressed to each other without any filler material; brazing joins two parts
without melting them but through a fused filler metal.
Surface cleaning and brazing fluxes

✓ Capillary effect is achieved by both: a proper surface preparation and

use of a flux for wetting and cleaning the surfaces to be bonded.

✓ Contaminants to be removed from the part surface are: mineral oils,

miscellaneous organic soils, polishing and buffing compounds,
miscellaneous solid particles, oxides, scale, smut, rust.

✓ The work pieces are cleaned by means of mechanical methods, soaking

cleaning and chemical cleaning (acid etching).

✓ A brazing flux has a melting point below the melting point of the filler
metal, it melts during the heating stage and spreads over the joint area,
wetting it and protecting the surface from oxidation. It also cleans the
surface, dissolving the metal oxides.
It is important that the surface tension of the flux is:

✓ Low enough for wetting the work piece surface;

✓ Higher than the surface tension of the molten filler metal in order to provide
displacement of the flux by the fused brazing filler. The latter eliminates the
flux entrapment in the joint.
The flux is applied onto the metal surface by brushing, dipping or spraying. Brazing filler
materials
✓ Copper filler alloys: BCuP-2 (Cu-7P), BCuP-4 (Cu-6Ag-7P). Used for brazing Copper
alloys, Steels, Nickel alloys.
✓ Aluminum filler alloys: Al-4Cu-10Si, Al-12Si, Al-4Cu-10Si-10Zn, 4043 (Al-5.2Si), 4045
(Al-10Si). Used for brazing Aluminum alloys.
✓ Magnesium filler alloys: BMg-1 (Mg-9Al-2Zn), BMg-2 (Mg-12Al-5Zn). Used for brazing
Magnesium alloys.
✓ Nickel filler alloys: BNi-1 (Ni-14Cr-4Si-3.4B-0.75C), BNi-2 (Ni-7Cr-4.5Si-3.1B-3Fe),
BNi-3 (Ni-4.5Si-3.1B). Used for brazing Nickel alloys, cobalt alloys, Stainless steels.
✓ Silver brazing alloys: BAg-4 (40Ag-30Cu-28Zn-2Ni), BAg-5 (45Ag-30Cu-25Zn), BAg-6
(50Ag-34Cu-16Zn), BAg-7 (56Ag-22Cu-17Zn-5Sn). Used for most of metals and alloys
except aluminum and magnesium alloys.
Brazing Methods
Torch brazing utilizes a heat of the flame from a torch.
✓ The torch mixes a fuel gas with oxygen or air in the proper ratio and flow rate,
providing combustion process at a required temperature.
✓ The torch flame is directed to the work pieces with a flux applied on their surfaces.
✓ When the work pieces are heated to a required temperature, filler alloy is fed into
the flame.
✓ The filler material melts and flows to the gap between the joined parts.
✓ Torch brazing is the most popular brazing method.
✓ Torch brazing equipment:
✓ Fuel gas cylinder with pressure regulator;
✓ Oxygen cylinder with pressure regulator;
✓ Welding torch;
✓ Blue oxygen hose:
✓ Red fuel gas hose;
✓ Trolley for transportation of the gas cylinders.
Brazing Methods
✓ Furnace brazing uses a furnace for heating the work pieces.
✓ Vacuum brazing is a type of furnace brazing, in which heating is
performed in vacuum.
✓ Induction brazing utilizes alternating electro-magnetic field of high
frequency for heating the work pieces together with the flux and the
filler metal placed in the joint region.
✓ Resistance brazing uses a heat generated by an electric current
flowing through the work pieces.
✓ Dip brazing is a brazing method, in which the work pieces together
with the filler metal are immersed into a bath with a molten salt.
The filler material melts and flows into the joint.
✓ Infrared brazing utilizes a heat of a high-power infrared lamp.
 COMPARISON OF SOLDERING, BRAZING AND WELDING
Welding Soldering Brazing

These are the strongest joints used These are weakest joint out of These are strongest than soldering but
to bear the load. Strength of a three. Not meant to bear the weaker than welding. These can be used
welded joint may be more than the load. Use to make electrical to bear the load upto some extent.
strength of base metal. contacts generally.
Temperature required is upto 3800⁰C Temperature requirement is upto It may go to 600⁰C in brazing.
of welding zone. 450⁰C.

Workpiece to be joined need to be No need to heat the workpieces. Workpieces are heated but below their
heated till their melting point. melting point.
Mechanical properties of base metal No change in mechanical May change in mechanical properties of
may change at the joint due to properties after joining. joint but it is almost negligible
heating and cooling.
Heat cost is involved and high skill Cost involved and skill Cost involved and sill required are in
level is required. requirements are very low. between others two.
Heat treatment is generally required No heat treatment is required. No heat treatment is required after
to eliminate undesirable effects of brazing.
welding.
No preheating of workpiece is Preheating of workpieces before Preheating is desirable to make strong
required before welding as it is soldering is good for making good joint as brazing is carried out at
carried out at high temperature. quality joint. relatively low temperature.
Soldering and Brazing

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Thank you