Chapter 3

Module 3: Welding (Brazing)

Table of Contents

Welding 3-2
Brazing Terms and Definition (ISO 857-2-2005) 3-3
Difference between Soldering and Brazing 3-4
Brazing terms and definitions (ISO 857-2-2005) 3-3
Equipment for the Oxy-acetylene Process… 3-5
Oxy-Acetylene Flame 3-6
Setting Up and Shutdown Brazing Touch 3-8
Setting up an oxyacetylene torch and Safety 3-10
Methods of Testing Oxy-Fuel System for Leaks 3-12
Brazing Technique 3-16

Reference 1-

Table of Figure

What you will cover

Module 2
 Welding
 Brazing terms and definitions (ISO 857-2-2005)
 Difference between Soldering and Brazing
 Equipment for the Oxy-acetylene Process
 Oxy-Acetylene Flame
 Setting up an oxyacetylene torch and Safety
 Methods of Testing Oxy-Fuel System for Leaks
 Brazing Techniques

Learning Outcome
At the end of this module participants will be able to:
Understanding Oxy-Acetylene application in Refrigeration and Air-Condition System
Understand Welding, Soldering and Brazing and application
Understand Advantages and Disadvantages of Brazing
Identify the methods of testing Oxy-acetylene equipment

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Welding

To weld is to join two pieces of metal together. It can just involve pressure, but this is usually
aided by some form of heating and varies from heat weld to electrical resistance spot welding.
Heating is also used to enable bonding to occur when soldering or brazing and to melt the metal
the infusion welding. Heat energy sources can be electrical, chemical, mechanical, light and
sound.

So welding can be done hot or cold, with or without pressure and with or without melting, with
or without filler addition, manually or automatically and so on, but it will certainly involve the
joining of metal.

Welding is typically chosen for metal joining because it offers strength and permanently.
Mechanical devices such as bolts, set pins, screws and so on offer some alternatives which are
typically fairly easy to apply, and can be taken apart/reassembled easily, although they may
perhaps lack the strength or the ability to retain fluids that welding offers.

Importance of welding
Welding is a material joining process performed by application of heat with or without pressure
and addition of filler material. The applications of welding are so varied and extensive that it
would be no exaggeration to say that there is no metal industry and no branch of engineering
science that does not make use of welding in one form or another. Varying from small scale
industry to large scale industry and from small machines to large machineries, welding is applied
everywhere. Construction of large ships, bridges, huge buildings, railways, roadways, automotive
and aircraft construction, pipe lines, tanks and vessels, machinery parts depend a lot on welding
technology.
Classification of Welding
Modern methods of welding can be classified, depending on the state of the material during
welding (plastic or molten state), as follows:
 Plastic welding or pressure welding
 Fusion welding or non-pressure welding

They can also be classified, depending on the source of heat, as follows:

 Gas welding
 Oxy acetylene or hydrogen welding
 Air acetylene welding
 Arc welding
 Carbon arc welding
 Metal arc welding
 Gas metal arc welding (MIG)
 Plasma arc welding
 Electro slag welding
 Submerged arc welding
 Other (See Table)

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Some of the most important welding processes are explained below:

 Plastic welding or pressure welding:
In this process, the piece of metal to be joined is heated to a plastic state and then forced
together by external pressure.
 Fusion welding or non-pressure welding:
In this type of welding method, the material at the joint is heated to a molten state and allowed
to solidify. This include gas weld, arc weld etc.
 Oxy-Acetylene/ fuel gas welding:
Oxyacetylene gas welding is commonly used to permanently join mild steel. A mixture of oxygen
and acetylene burns as an intense / focussed flame, at approximately 3,500 degrees centigrade.
When the flame comes in contact with steel, it melts the surface forming a molten pool, allowing
welding to take place.

Oxyacetylene can also be used for brazing, bronze welding, forging / shaping metal, Soldering
and cutting. This type of welding is suitable for the prefabrication of steel sheet, tubes and
plates.

Brazing terms and definitions (ISO 857-2-2005)

Soldering and Brazing definition

ISO 857-2-2005 3.1 defines soldering/brazing joining processes in which a molten filler material
is used that has a lower liquidus temperature than the solidus temperature of the parent
material(s), which wets the surfaces of the heated parent material(s) and which, during or after
heating, is drawn into (or, if pre-placed, is retained in) the narrow gap between the components
being joined

ISO 857-2-2005
3.1.1 Soldering: joining process using filler metal with a liquidus temperature of 450 °C or less
3.1.2 Brazing: joining process using filler metal with a liquidus temperature above 450 °C
3.1.4 Filler metal spreading and gap filling
3.2.1 Filler metal: added metal required for soldered or brazed joints, which can be in the form
of wire, inserts, powder, pastes, etc.
3.2.2: flux non-metallic material which, when molten, promotes wetting by removing existing
oxide or other detrimental films from the surfaces to be joined and prevents their re-formation
during the joining operation

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Difference between Soldering and Brazing

Soldering: It is a process in which two or more items (usually metal) are joined together by
melting and putting a filler metal (solder) into the joint, the filler metal having a lower melting
point than the adjoining metal.

Soldering differs from welding in that soldering does not involve melting the work pieces. In the
past, nearly all solders contained lead, but environmental and health concerns have increasingly
dictated use of lead-free alloys for electronics and plumbing purposes. Soldering is used in
plumbing, electronics, and metalwork from flashing to jewellery.

Advantages of Brazing
The family of brazing processes in common use is extremely wide. It encompasses the joining of a
large number of different combinations of parent materials and a wide selection of filler materials
and oxide removal procedures, combined with a variety of joint designs and heating methods.
Provided the parent materials to be joined have a melting point that is above 450ºC, with attention
to detail and careful thought, it is not overstating the case to say that they will be able to be joined

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by brazing. Whether this will provide the best-practice joining procedure for the joint in question
is another matter; this can be determined only from the results of a process analysis.

Equipment for the Oxy-acetylene Process

Oxygen
Oxygen, which makes up about 21 percent of the air. Oxygen not only combines with carbon and
hydrogen to produce energy (heat), but combines with most of the other elements found in the
universe, including all metals.
However, almost everything made up predominantly of carbon and hydrogen (coal, wood,
petroleum products) has a”kindling temperature”. Once that temperature is reached,
”oxidation” suddenly becomes ”burning”, which then proceeds to produce enough heat to
maintain the reaction until the supply of oxygen or fuel runs out, or until other influences
produce enough cooling effect to quench the fire.

Oxygen is produced by fractional distillation of liquid air and stored in cylinders with a filling
pressure of up to 200 bar. For higher oxygen consumption, storage in a liquid state and cold
gasification is more profitable. The standard cylinder (40 litres) contains, at a filling pressure of
150 bar, 6m³ of Oxygen. Moreover, cylinders with contents of 10 or 20 litres (150 bar) as well as
50 litres at 200 bar are common.

Acetylene
Acetylene is a”hydrocarbon”, just as are propane, methane, and virtually all the components
which make up gasoline and fuel oils. When acetylene reaches its kindling temperature the bond
breaks and releases energy. The triple bond in acetylene is the reason why the oxy-acetylene
flame is hotter than the flame produced by burning any other hydrocarbon gas with oxygen.
Virtually all the acetylene distributed for welding and cutting use is created by allowing calcium
carbide, an electric furnace product, to react with water.

The real ”tool” of the oxy-acetylene brazing process is the flame, not the torch. When we come
to oxygen brazing, we must consider the pure oxygen jet as a second ”tool”, working hand-in-
hand with the flame. To produce only the flame, we use a brazing torch, fitted with the
appropriate size brazing head or tip. To produce both flames and the oxygen jet, we use a
brazing torch or attachment, equipped with the appropriate cutting nozzle or tip. The equipment
needed for oxy-acetylene brazing is relatively simple and inexpensive.

Acetylene, which is dissolved in acetone contained in a porous material. To prevent

decomposition during use, acetylene gas system pressures must not exceed 1.5 bar.

If the gases are to be supplied in cylinders, these are the minimum requirements:
 A cylinder of oxygen
 A cylinder of acetylene
 A brazing attachment, with one or more nozzles
 A length of oxygen hose, with fittings
 A cylinder pressure regulator for oxygen
 A length of acetylene hose, with fittings
 A cylinder pressure regulator for acetylene Goggles and gloves for the operator
 A brazing torch, with one or more welding heads
 A friction lighter for igniting the flame

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Identification of gas cylinders

Gas cylinders are colour-coded.
An oxygen cylinder is blue with; and an acetylene cylinder is maroon. Cylinders should also carry
a label that gives details of the type of gas.

Oxy-Acetylene Flame

Properties of the Acetylene Flame

Acetylene is composed of Hydrogen and Carbon, as are most fuel gases. It is mainly the carbon
which provides the intense heat and very high flame. If the oxygen is turned down to provide a
flame with excess carbon, the carbon is taken into the steel to provide a high carbon surface,
used for hard surfacing operations.

The oxy-acetylene flame is the hottest flame available. Its temperature of 6300 ®F is 2000 degree
higher than any other flame. This high temperature allows work to be done quickly and with a
slight loss of heat due to conduction and radiation. If sufficient oxygen is not provided, then the
carbon is given off into the air as black, sooty smuts.

A neutral oxy-acetylene flame burns equal proportions of oxygen and acetylene and is reducing
in nature, thereby reducing any iron oxide to iron and taking up the oxygen; consequently there
is no need to use a flux when welding steel. It should be noted that iron oxide is not refractory.

Adjusting an Acetylene Flame

There are three phases of acetylene flame:
 the neutral or welding flame;
 the carbonizing or reducing flame; and
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 the oxidizing flame.

Each of these have its own characteristics and it takes only a little practice to identify them.
These are achieved by varying the proportions of acetylene gas in relation to the proportion of
oxygen gas at the welding nozzle.

Neutral Flame
This flame burns equal quantities of oxygen and acetylene. (In practice, it is advisable to have the
slightest possible acetylene haze at the cone tip to begin with.)

2. Carburizing Flame
This flame has an excess of acetylene which results in a carbon-rich zone extending around and
beyond the cone.
Note: Both the Neutral and Carburizing flames are reducing in nature.

3. Oxidizing Flame
This flame has an excess of oxygen which results in an oxygen-rich zone just beyond the cone.
This flame is obtained by setting to neutral and then turning the fuel gas down.

Nozzle Sizes
For a given welding torch, the NOZZLE OUTLET SIZE has a much greater influence on governing
the flame size than changing the gas pressures on adjusting the control valves. The
manufacturers of gas welding equipment have adopted various methods of indicating nozzle
sizes, such as:

 By the approximate consumption of each gas per hour.

 By the nozzle outlet bore size (orifice diameter).
 By a reference number corresponding to a metal thickness range which may be welded
with a specific nozzle.
Whatever the method employed for indicating nozzle sizes there is a definite relationship
between the sizes of welding nozzles and the metal thicknesses.

Nozzle Selection and Working gas pressures

As the thickness of the work increases, the flame will be required to supply more heat. This is
made possible by increasing the nozzle size and the regulator gas pressures (in accordance with
manufacturers’ instructions).

If you try to weld thick metal with a small nozzle by increasing the gas pressure, there comes a
point where the flame leaves the end of the nozzle.
This indicates that the pressure is too high, resulting in a very noisy flame. It is much better to
work with a 'soft' flame, which is obtained by using the correct nozzle size and pressure settings.

At the other extreme, if you try to weld with a nozzle that is too large for the work, by reducing
the supply of gas at the blowpipe valves instead of changing to a smaller nozzle, then small
explosions will occur at the nozzle. This is because the gas tends to build up round the nozzle in
small bubbles. These small explosions indicate that the gas pressure is too low.

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The table below lists typical nozzle sizes and gas pressures for oxyacetylene welding. Always
consult the manufacturer’s information, as this information can vary slightly with different
makes of blowpipe.

Mild Steel Operating Consumption Of

Thickness Brazin Pressure Gas
g
Acetylen
(mm) SWG Nozzle e
Oxygen Acetylene Oxygen
(bar) (l/h) (l/h)
(bar)
0.9 20 1 0.14 0.14 85 85
1.2 18 2 0.14 0.14 110 110
2 14 3 0.21 0.21 170 170
2.6 12 5 0.21 0.21 200 200
3.2 10 7 0.21 0.21 250 250
4 8 10 0.21 0.21 280 280
5 6 13 0.28 0.28 400 400

Note: Gas consumption data is merely for rough estimating purposes. It will vary greatly on the
material being welded and the particular skill level of the operator.

Setting Up and Shutdown Brazing Touch

Step-by-Step Instruction
1. Equipment assembly: Ensure that the equipment is assembled correctly as in figure 1
above
2. Check equipment: First, make sure that the gas flow from both the oxygen and the
acetylene cylinders is turned off tightly. The two cylinders are secured in an upright position.
This is usually on a wheeled trolley. Look at the hose pressure and cylinder pressure gauges
on top of each cylinder. Both gauges on each cylinder should read zero. If both gauges do not
read zero, turn the main cylinder valve on the top of the cylinder clockwise, to close it
completely. Then you must purge the system of any gas.

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3. Purge the system: To purge the system, make sure the main cylinder valve is close tightly.
Pick up the torch handle and note that it has two hoses attached. One hose supplies
acetylene, the other oxygen.
Turn the oxygen regulator under the gauges clockwise, and open the oxygen valve on the
handle. This will purge any gas that may still be in the system and the gauges should both
drop back to zero. Repeat this procedure with the acetylene cylinder.

4. Install the torch handle: The torch handle is the connection between the hoses and the
working tips. It consists of a body and two taps. It’s used for both welding, Brazing and
heating. Different attachments are connected to the handle to enable cutting. Examine the
connections. One connection is marked “OX”, and is for the oxygen hose. The other is
marked “AC”, and is for the acetylene hose.

5. Connect the hoses: As a further safety precaution, you’ll find the oxygen connector is right
hand thread and the acetylene connector is a left hand thread.

6. Install the correct tip: Welding tips come in sizes that are stamped with a number. Number
one is the smallest tip. The larger the number, the larger the tip and the greater the heat that
it will provide. Select the tip size suitable for the task and screw it onto the end of the torch
handle. Hold the torch handle in your hand, so that you can comfortably adjust the oxygen
and acetylene taps. Position the tip so that it faces away from you. Gently tighten the tip-
securing fitting.

7. Adjust the pressure of the gas flow: You are now ready to adjust the gas pressure for
heating. Look at the two valves on the torch handle. The valve next to the oxygen hose
controls the flow of oxygen to the tip. Close it tightly clockwise. The valve next to the
acetylene hose controls the flow of acetylene to the tip. Also, close it tightly clockwise.

8. Turn on the gases: Now that you’re ready to use the torch, turn the main valve on the top
of each cylinder counter-clockwise half a turn to open the valve. The needle on the cylinder
pressure gauge will rise to show you the pressure in the cylinder. Turn the oxygen regulator
handle clockwise until the needle in the gauge registers 2-5 PSI. Turn the acetylene regulator
handle clockwise until the needle in the gauge registers 2-5 PSI. This is your working pressure
for welding light plate.

9. Check the area: Before you light the torch, check the area you’re working in to make sure
there are no flammable materials or fluids nearby. Workmates should also be clear of the
area. The welding flame is not only extremely hot; it also produces dangerous ultra violet
rays, which will damage your eyes. It is absolutely vital that you are wearing the right safety
gear: gloves and tinted goggles or face mask. So put them on and adjust them comfortably.

10. Ignite the torch: Now you are ready to ignite the torch with the striker. The tip of the
torch must be pointing downwards away from your body and away from the gas cylinders.
Turn the acetylene valve on the torch handle slightly towards the ‘ON’ position. You should
hear the gas hissing. Hold the striker against the tip of the torch with the lighter cup between
the torch and you. Flick the striker to create the spark that will ignite the gas at the tip of the
torch. Open the acetylene valve slowly until the sooty smoke produced by the torch
disappears. Then slowly open the oxygen valve on the torch handle.

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11. Adjust the flame: As you open the oxygen valve, you will see the colour of the flame
change. The pure acetylene flame is yellow, and it will change to blue as you add the oxygen.
Continue to open the oxygen valve until you can observe a small, sharp blue cone in the
centre of the torch flame. This is the “neutral”, you can now adjust to the desired flame, for
the task you are doing. (Welding, brazing)

Shut Down
When you have finished the job, you will need to shut down the equipment. Turn off the
acetylene valve on the torch handle. This will extinguish the flame. Turn off the oxygen valve on
the torch handle. Next, remove your safety goggles or mask and your welding gloves. Turn the
main cylinder valve clockwise on the top of both gas cylinders. Now open the two valves on the
torch handle to “bleed” the system. Turn both the oxygen and acetylene regulator handles
counter-clockwise until they are loose. Close both valves on the torch handle. Put the handle and
tips away and return the gas cylinders and their hoses to their proper storage area.

Setting up an oxyacetylene torch and Safety

Oxy-acetylene torch can produce a large amount of heat. Be aware that any objects you direct
the flame towards will become hot. Always light the oxyacetylene torch with the striker. A
cigarette lighter or match would put your hand too close to the igniting tip. The objective of this
procedure is to show you how to set up an oxyacetylene torch for heating.

Lighting procedure:
 Check regulator thumb screws
 Turn on the oxygen valve all the way
 Set the correct oxygen working pressure
 Open fuel cylinder valve one half turn
 Set the correct fuel working pressure
 Light the flame
 Shut down the flame (Fuel first)
 Turn of the fuel cylinder valve
 Empty fuel hoses until gages register zero
 Turn off the oxygen cylinder valve
 Empty the oxygen hose until gages register zero
 Loosen regulator thumbscrews.

When Brazing:
 Always wear protective clothing, i.e. flame retardant overalls
 Always wear the correct eye goggles
 Always have the spindle key in the acetylene cylinder valve
 Always keep cylinders secured in an upright position
 Always check for leaks with a soapy solution, NEVER with a naked flame.
 Never carry out makeshift repairs on welding equipment.
 Never allow oil or grease to come in contact with oxygen equipment.
 Never weld an enclosed vessel, i.e. petrol / oil drums until they have been thoroughly
cleaned.
 Never work in an enclosed vessel on your own and always leave the cylinders outside. If
working in an enclosure vessel, adequate ventilation should be provided and fire-fighting
equipment should be available.

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 In the event of a serious flashback or backfire plunge the blowpipe in a bucket of cold
water, leaving the oxygen running to prevent water entering the blowpipe.
 Should the hoses become damaged, turn off the supply of gas at the cylinder and inform
your instructor.
 Don’t forget, this equipment, if misused or damaged, can be dangerous.
 If in any doubt seek assistance and clarification from your instructor

Safety check
 Oxygen and acetylene cylinders must be securely stored in an upright position.
 An oxyacetylene torch can produce a large amount of heat. Be aware that any objects
you direct the flame towards will become hot.
 Always have a suitable fire extinguisher near your work area.
 Do not use an oxyacetylene torch near any flammable materials.
 Make sure that you understand and observe all legislative and personal safety
procedures when carrying out the following tasks. If you are unsure of what these are,
ask your supervisor.

Personal safety
Whenever you perform a task in the workshop you must use personal protective clothing and
equipment that is appropriate for the task and which conforms to your local safety regulations
and policies. Among other items, this may include:
 Work clothing - such as coveralls and steel-capped footwear
 Eye protection - such as safety glasses and face masks
 Ear protection - such as earmuffs and earplugs
 Hand protection - such as rubber gloves and barrier cream
 Respiratory equipment - such as face masks and valve respirators
If you are not certain what is appropriate or required, ask your supervisor.

General Safety
 If a cylinder falls over and breaks the main valve off, the cylinder will become a missile
and cause extreme damage.
 Wear a leather apron or similar protective clothing and welding gloves when using an
oxyacetylene torch. T-shirts, nylon and polyester blend clothing will not provide enough
protection. Ultraviolet light and sparks of hot metal will pass through them.
 Always use proper welding goggles. Do not use sunglasses because they do not filter the
extreme ultraviolet light as effectively. The plastic used in sunglass lenses will not protect
your eyes from sparks.
 Never point the lighted flame toward another person or any flammable material.
 Always light the oxyacetylene torch with the striker. A cigarette lighter or match would
put your hand too close to the igniting tip.
 Wherever possible, use a heat shield behind the component you are heating. This will
prevent nearby objects from becoming hot.
 After heating a piece of metal, label it as "HOT" with a piece of chalk so that others will
not attempt to pick it up.

Ventilation
In a confined space, ensure that there is a suction fan to give adequate ventilation (a fume hood,
at the source of fumes, is the best method); DO NOT USE OXYGEN OR AN AIR BLOWER and
always post a trained helper outside for emergencies.

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Test all equipment for leaks before entering and remove the equipment outside during periods
when it is not in use and on completion of daily work.
The welding of brass or galvanised materials should be carried out in well ventilated areas and if
the work is likely to be prolonged suitable breathing apparatus should be worn.
When brazing painted or galvanised steel, unless ventilation is very good, fume extraction should
be installed at the point of cutting.
In some cases it may be necessary to wear a respirator as well.

Methods of Testing Oxy-Fuel System for Leaks

Leak detection
Valves, pressure-reducing regulators, hoses, torches, and their associated connections can leak.
Drop testing uses a cylinder’s own internal pressure with the regulator’s pressure gauges to
detect a leaking oxygen or fuel-gas system. This system test, required at the beginning of each
shift, detects when there is a leak between the closed valves on the container and torch handle.

Precautions:
You should take suitable precautions when checking for gas leaks.
You should use a proprietary leak detecting spray or solution suitable for use with oxy/fuel
systems. Soapy water or solutions containing grease should not be used on oxygen equipment.

Drop test procedure

 Ensure that both the oxygen and fuel control valves on the torch handle are closed.
 With the oxygen cylinder valve open, adjust the oxygen regulator to deliver a minimum of
1.4 bar.
 With the fuel cylinder valve open, adjust the fuel regulator to deliver a minimum of
0.7 bar.
 Close both the oxygen and fuel-gas cylinder valves.
 Turn the adjusting screws counter clockwise to relieve regulator pressure.
 Observe the gauges on both regulators for a minimum of five minutes.

A change in the pressure gauge readings results in a failed drop test. A failed drop test confirms a
leak exists, not the leak’s location.

Leak testing is required following a failed drop test. Leak testing uses a liquid solution, or another
accepted method, to pinpoint the leak’s location. Solutions must be compatible with the gas
being checked. Never use a solution containing petroleum to check for an oxygen leak. Always
test for leaks before transporting cylinder.

When the leak is found, you should repair or replace the component immediately. Any detergent
should be flushed off with clean water to remove any corrosive salts. You must never look for gas
leaks with a naked flame.

If a cylinder leaks when the valve is closed, the cylinder should be taken outside to a ventilated
area, away from sources of ignition (naked flames, sparks, electric lights and motors, etc) and
unauthorised access. You should notify the supplier immediately.

Brazing Techniques
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The importance of correct procedures

A brazed joint "makes itself" – or that capillary action, more than operator skill, insures the
distribution of the filler metal into the joint. The real skill lies in the design and engineering of
the joint. But even a properly-designed joint can turn out imperfectly if correct brazing
procedures are not followed.

These procedures boil down to six basic steps. They are generally simple to perform (some may
take only a few seconds), but none of them should be omitted from your brazing operation if you
want to end up with sound, strong, neat-appearing joints.

For the sake of simplicity, we'll discuss these six steps mainly in terms of "manual brazing," that
is, brazing with hand-held torch and hand-fed filler metal. But everything said about manual
brazing applies as well to mass production brazing.
The same steps must be taken, although they may be performed in a different manner.

Basic steps in brazing

1. Ensure fit and clearance
2. Clean metal
3. Flux prior to brazing
4. Fixturing of parts
5. Brazing the assembly
Cleaning the new joint

Step 1: Good fit and proper clearances

Brazing, as we've seen, uses the principle of capillary action to distribute the molten filler metal
between the surfaces of the base metals. Therefore, during the brazing operation, you should
take care to maintain a good clearance between the base metals to allow capillary action to
work most effectively.

Step 2: Cleaning the metals

Capillary action will work properly only when the surfaces of the metals are clean. If they are
"contaminated" - coated with oil, grease, rust, scale or just plain dirt - those contaminants have
to be removed. If they remain, they will form a barrier between the base metal surfaces and the
brazing materials. Brazing filler metal won't bond to a rusty surface. Cleaning the metal parts is
seldom a complicated job, but it has to be done in the right sequence. Oil and grease should be
removed first, because an acid pickle solution aimed to remove rust and scale won't work on a
greasy surface

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Step 3: Fluxing the parts

The phosphorus content of the Sil-Fos alloys permits copper-to-copper brazes to be
accomplished without the use of a brazing flux. In general, when brazing copper to mild steel or
mild steel to mild steel, the filler metal used is brass , a brazing flux is required.
Flux is a chemical compound applied to the joint surfaces before brazing. Its use is essential in
the brazing process. It removes oxides from the surface of the brazed metal. It makes the filler
metal to flow easily.

Step 4: Assembly for brazing

The parts of the assembly are cleaned and fluxed. Now you have to hold them in position for
brazing. And you want to be sure they remain in correct alignment during the heating and
cooling cycles, so that capillary action can do its job. If the shape and weight of the parts permit,
the simplest way to hold them together is by gravity.

Figure 1

Or you can give gravity a helping hand by adding additional weight.

Step 5: Brazing the assembly; Proper Heating

The fifth step is the actual accomplishment of the brazing joint. It involves heating the assembly
to brazing temperature, and flowing the filler metal through the joint. First, the heating process.
As we've seen in brazing, you apply heat broadly to the base metals. If you're brazing a small
assembly, you may heat the entire assembly to the flow point of the brazing filler metal. If you're
brazing a large assembly, you heat a broad area around the joint. The heating method most
commonly used in brazing a single assembly is the hand held torch.

All you have to keep in mind is that both metals in the assembly should be heated as uniformly
as possible so they reach brazing temperature at the same time. When joining a heavy section to
a thin section, the "splash-off" of the flame may be sufficient to heat the thin part. Keep the
torch moving at all times and do not heat the braze area directly. When joining heavy sections,
the flux may become transparent - 593°C - before the full assembly is hot enough to receive the
filler metal. Some metals are good conductors - and consequently carry off heat faster into
cooler areas. Others are poor conductors and tend to retain heat and overheat readily. The good
conductors will need more heat than the poor conductors, simply because they dissipate the
heat more rapidly.

In all cases, your best insurance against uneven heating is to keep a watchful eye on the flux. If
the flux changes in appearance uniformly, the parts are being heated evenly, regardless of the
difference in their mass or conductivity. You've heated the assembly to brazing temperature.
Now you are ready to deposit the filler metal. In manual brazing, all this involves is carefully
holding the rod or wire against the joint area. The heated assembly will melt off a portion of the
filler metal, which will instantly be drawn by capillary action throughout the entire joint area.
You may want to add some flux to the end of the filler metal rod - about 51 mm to 76 mm - to
improve the flow. This can be accomplished by either brushing on or dipping the rod in flux.
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 Module 3: Welding (Brazing)

Step 6: Cleaning the brazed joint

After you've brazed the assembly, you have to clean it. And cleaning is usually a two-step
operation. First - removal of the flux residues. Second - pickling to remove any oxide scale
formed during the brazing process. Flux removal is a simple, but essential operation. (Flux
residues are chemically corrosive and, if not removed, could weaken certain joints.) Since most
brazing fluxes are water soluble, the easiest way to remove them is to quench the assembly in
hot water 50°C or hotter. Best bet is to immerse them while they're still hot, just making sure
that the filler metal has solidified completely before quenching. The glass-like flux residues will
usually crack and flake off. If they're a little stubborn, brush them lightly with a wire brush while
the assembly is still in the hot water

Brazing Similar and Dissimilar Metal

Copper to Copper
Pre-Cleaning: The formation of surface oxides on copper tube and fittings and other metals is
unavoidable when these materials are exposed to the atmosphere. In order to maximize a good
covalent bond between the brazed parts and the filler metal, these surface oxides must be
removed, either chemically, or with an abrasive material or file. If there is a presence of oil or
grease on the parts, it should be removed with a solvent prior to mechanical oxide removal.
Cleaning of the parts to be brazed is very important because the presence of these oxides or
contaminants can prevent the flow or capillary action of the molten filler metal at the brazing
temperature.
Many failures or leaks in brazed joints can be avoided by proper pre-cleaning of the braze
assembly.

Temperature Matters: In the Refrigeration and Air-conditioning industry, the most widely-used
braze joint is the joining of copper tubes and fittings. The primary brazing alloy used for this
assembly is Sil-Fos, is a favourite because of its wide melting range – solidus temperature 645 0C
and liquidus temperature 8070C. The advantage of a wide range of flow temperature is that it
enables the operator greater control of the alloy during brazing.

The temperature to be used is slightly higher than carburizing flame

At the high end of the melting range the alloy flows thinner and is able to penetrate into the
tightest areas of the joint assembly. By reducing the temperature during brazing, the alloy flows
thicker and can fill wider gaps while creating a cap or fillet on the assembled joint.

Proper Heating: When brazing a copper to copper tube, it is a good practice to concentrate the
heat on all side so that the heat is conducted through the copper into the interior and external of
the assembly to bring both pieces up to brazing temperature at the same time. In order to get a
strong covalent bond on all surfaces to be joined, the parts of the assembly need to be uniformly
or simultaneously heated to brazing temperature when the brazing alloy is applied. When all
parts are up to the proper temperature the filler metal can flow without restriction and bond
with the base metal in a very short amount of time. Prolonged heating cycles and overheating
can cause serious problems in the brazing process.

Operator Attention is Key:

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 Module 3: Welding (Brazing)

All of these considerations – pre-cleaning, liquidus temperature, alloy content, and proper
heating are primary concerns. However, the most important factor in the brazing process is the
focus of the brazing operator. Always consider each aspect of the brazing process before you
begin.

Copper to Mild Steel OR Mild Steel to Mild Steel

The above factor for copper to copper are equally applicable:
Pre cleaning, the right Filler metal, temperature, proper heating and operator attention. There
other factor to be considered.

Proper clearances: This tubular assemblies in which dissimilar metals are joined the "coefficient
of thermal expansion" must take into account. Copper expands, when heated, more than mild
steel. Allow enough initial clearance, so that the gap at brazing temperature will just be right to
accommodate the filler metal with a resultant effect after the temperature is cooled you will
have a good brazed joint.

Pre-Cleaning: It is very important that the two external and internal surfaces be cleaned before
brazing. Copper to copper can be tolerated.

Flux and filler Metal: The phosphorus content of the Sil-Fos alloys permits copper-to-copper
brazes to be accomplished without the use of a brazing flux.
When brazing copper to mild steel, a brazing flux is required.
The Filler metal is usually brass.

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