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Arc Welding

The document provides an overview of welding processes, including definitions, advantages, and disadvantages of welded joints, as well as types of welding such as arc welding, brazing, and soldering. It discusses factors affecting weldability, types of welded joints, edge preparation, and various arc welding processes. Additionally, it highlights the importance of safety precautions and equipment used in welding operations.

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adevic0508
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38 views29 pages

Arc Welding

The document provides an overview of welding processes, including definitions, advantages, and disadvantages of welded joints, as well as types of welding such as arc welding, brazing, and soldering. It discusses factors affecting weldability, types of welded joints, edge preparation, and various arc welding processes. Additionally, it highlights the importance of safety precautions and equipment used in welding operations.

Uploaded by

adevic0508
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF or read online on Scribd
ARC AND GAS WELDING, BRAZING AND SOLDERING INTRODUCTION Definition of some terms Weld; A weld is a coalescence of metals produced by heating to a suita®': temperature with or without the application of pressue, and with or without the ' use of a filler metal. Weldability; The property of a metal whick indicates the ease with which 1 similar or dissimilar metals are joined by fusion with 0+ without the application Pressure and with or without the use of filler metal. Striclly speaking, a metal has good weldability if it can by easily welded in a fabricat-c structure. The following are factors affecting the weldabil 1. Composition of the meta. y ofa metel; \: 2. Brittleness and strength of the metal at elevated ternperaiures, 3. Thermal properties of the metal. 4. Welding techniques, fluxing material and filler meterial. 5. Proper heat treatment betore and after the deposition of te moval, The common metals havins, weldabiiity in the deScending or ier are iron, carbogysteel, iron, low alloy steels and stuinless steel. Advantages and Disadvantages of Welded Joints Following are the advantages and disadvantages of welded joints over other joints such as riveted or bolted joints. Advantages. 1. The welding structures are normally fighter than rive:2d or bolted structures. This is due to the reason, that in welding, gusscts or other connecting componen.s er used. 2. The welded joint jwovides maximum efficiency ‘inay be 100%) which is n> possible in other typ of joints. 3. The alterations and sidditions can be casily -aade in the: existing struct 4. As the welding structure is smooth in appearance, 5. In welded connections, the tension me«mnbers are not weal joints. 6. A welded joint has a great strength. Often a welded parch metal itself. 7. Sometimes, the members are of such # afford difficulty in riveting. But they © 8. The welding provides very rigid joints providing rigid frames. 9. Itis possible to any part of a structure at ny point 10. The process of welding “akes less time than other type Disadvantages It requires a highly skilied labour and supervision. . The edge preparation is generally required bef Since no provision is left for at this moment. usually welded by 4 C ~All types of electrodes cannot be used in : velding because the currect constantly reverses with every cycle. Only Coated electrodes can be used. ~ The problem of “arc blow" does not arise as it is Very easy to conrol 6. The are is never stabie. 7. Itcan be used only when A.C. supply dom the mains is available. 8. A.C. is more dangerous. TYPES OF ARC WELDING Following are the two types of are welding depend: ipon the type of elecmode: 1. Unshielded are welding. When 2 p . Shielded arc welding. When the weiding rods then it is called shielded arc welding. The duxing mat al is applied to the rod . is comparatively less danger: dipping or extrusion. These rods are sometimes called costed clectodes. The coated rods not only supply a Tuxing agent but it also fuses st a slower rate than the nad itself. This property acts to exclude the atmosphere in th: Vicinity of the atmosphere and prevents the absorption of large amounts of harmful oxygen and nitrogen, Electrodes for Are Welding The electrodes for arc welding are generally of the following two types: 1. Bare or non-coated electrodes 2. Coated electrodes. ey When the bare or non-coated electrodes are used, then the deposited iy pr eeera s hot will absorb oxygen and nitrogen from the atmosphere. The © isto i cs hardness ang : i nitrogen promotes hardness ang produce inclusions and blow holes in the weld ani serene brittleness. This decreases the strength of the weld metal lowers its t to corrosion. The bare electrodes are rarely used in modern- welding practice. The equipment commonly used for welding consists of the following: 1. Alternating current (A.C.) or Direct current (D.C.) machines 2. Electrode; 3. Electrode holder (insulated) 4. Cables, 5. Cable connectors 6. Cable lugs 7. Chipping hammer 8. Earthing clamps 9. Wire brush 10. Heimet or hand shiek 11. Safety goggles 12. Hand gloves 13. Aprons, sleeves etc. Precautions in Are Welding The following precautions should be stricily observed while performing electric arc welding. 1. The hand, face and eyes should be protected from the heat and flare of the electric are. For this, the operator should wear hand gloves tc protect hands and a hand shield or helmet with a window of colored glass should be used to protect face and eyes. 2. The space for the electric are welding should be screened off from the rest of the building so that other workmen are safe from the glare of the arc which is very harmful for eyes. ARC WELDING PROCESSES ‘The following are the various are welding processes commonly used in engineering practice. 1. Carbon are welding, 2. Metal arc welding, 3. Metallic inert gas (MIG) arc welding, 4. Tungsten inert gas (TIG) arc welding, 5, Atomic hydrogen welding, 7. Submerged arc welding, 9. Flux cored arc welding. 11. Electro-gas welding. 6. Stud welding, 8. Plasma arc welding, 10 Electro-slag welding CARBON ARC WELDING (a). In welding fh ‘avy plates, the additional metal is deposited in the weld from a filler rod Filer etal Carbon sectrode (@) Welding with single (b) Welding with double carbon electrode, carbon slecrode. Carbon are welding. In another method, known as twin carbon are welding, two carbon electrodes are emp! between which the arc is formed. (b). In this way, the arc geaerates heat which is ap) close to the parts to be welded, causing the edges to fuse. In heavy welds, a filler rod is melted by the arc and deposited in the weld. The twin carbon arc welding is very sim to gas welding in which the heat is generated above the work and is played upon it. differences between the two are in the source of heat and cifferences in the atmos; around the work. In carbon are welding, a current of 20 to 800 amperes is used which depends upon the thickness of metal to be welded and diameter of electrode. Most of the carbon arc weldin: is done with automatic welding equipment where the arc volt=ge and current, rate of trav and rate of feeding the welding filler rod are all properly controlled. The carbon arc weldin, is used in all modem industries for welding cast iron, steel, copper, bronze, galvanized iron, aluminium and for rough cutting of metal Metal Arc Welding In metal arc welding, the arc is produced between the metal electrode (also called filler rod) and the work piece. During the welding process, the metal electrode is melted by the heat of the arc and fused with the work piece. The temperature produced by the heat is about 2400°C to 2700°C. The electrodes used in this process are straight pieces of metal Wire about 45 cm long and diameters ranging from 1.5 to 1) mm. The entire electrode (except for the bare end where it is held by the electrode holder) is covered with a* coating material. (180 9 1000 amps) tectode Source ot care workolace Basic set up for metal arc welding sees to be joined 5. When the metal pic ‘ plete the weld The metal are welding is normally a manua! proce’ are required (0 CON are relatively thick, then a number of individual po Metallic Inert-gas (MIG) Are Welding In metallic inert-gas are welding (commonly ku inert gas arc welding, except that the electrode is cons! wire (from 0.75 mm to 1.5 mm diameter) of desired composition continuously fed from a reel at a speed ranging from 250) to 750 em per minute metal is deposited by the arc which is completely surrounded hy an inert Bas: automat The filler Tungsten Inert-gas (TIG) Are Welding In ungsten-inert gas arc welding (commonly known as TIG welding), the heat is produced from an are between the non-consumable tungsten electrode and the work piece. The welding zone is shielded by an atmosphere of inert gas (such as helium or argon) supplied from a suitable source. The gas nozzle surrounds the tungsten clectrode Inert-gas arc welding In this process, either direct current or alternating current may be used, the selection depends upon the type of metal to be welded. The direct current with straight polarity is used for welding copper alloys and stainless steel, whereas th: reversed polarity is used for magnesium, The alternating current is more versatile in its aprlication and is used for steel, cect iron, aluminum and magnesium. Tbe process is capable of making clean sound welds in aluminum without the use of corrosive fluxes. Though any metal can be welded by this process, yet it is best suited forthe welding of relatively thin pieces of metal. The tungsten Inert e2s welding may be done either by a msmual process or by the automatic machine ‘welding, When it is manual, the welds can be made ix any position. Atomic hydrogen welding In atomic hydrogen welding, the arc is obtained between two tungsten electrodes (non- consumable) while a stream ‘of hydrogen passes by the are and envelops the welding zone. 10 eee the arc, the hi sonsisting of two atoms) inte vise temperature breaks up the molecules of hydrox 2 Y the hydrogen. Te toe: In doing so, a large amount of heat is required to recombine, especially when they Single hydrogen atoms then have a strong tendency When the stoms recombine no? @PP##ch the relatively coo surface ofthe work pice ¢ heat which was absorbed is liberated, producing Stud Are Welding The stud are welding i . <: studs to the mane wy 2 direct current arc welding process and is used for welding meta! Purpose. The stud i Surfaces, ». A machine known as stud welding gun is used for t against the surface when ait the stud welding gun and the front end of the gun is held : tere the stud is to be fastened. When the ti f the essed, eee a igger of the gun is presse: a ae cally goes through its welding cycle. The welding eyele starts by causing the Seiding current to flow between the end ofthe stud and the fat metal surface. The ond of Stud is then withdrawn by a small distance to create an arc Submerged Are Welding. In submerged arc welding, the arc is produced between a bare metal electrode and the work pisce. However, in this process, the region of the arc is completely submerged in a vanulated material. Plasma Arc Welding The plasma is a gas of positive ions and free electrons with an approximately equal positive and negative charge. In plasma are welding, the coalescence is produced by striking an arc between a tungsten electrode and a weter cooled nozzle. When gases are passed through the are and nozzle, they get ionized and become plasma. The gases generally used are argon. hydrogen or helium. The plasma stream of the ionized particles is passed through a small orifice of welding torch and made to impinge on to the area to be welded. The torch is held almost in vertical position to the base metal and filler metal wire is fed at a suitable angle. The plasma arc welding provides a deep penetration, faster welding, cleaner welds and narrow beads. It is used for welding stainless steel tubes, rockets, nuclear submarine plates, nickel and titanium alloy up to 8 mm thickness. Flux Cored Are Welding The flux cored arc welding uses a continuous hollow electrode wire containing flux within its hollow core. The equipment required is a constant voltage direct current machine, a welding gun with cooling arrangement and a continuous wire feeder mechanism. Sometimes additional shielding is provided with a gas and then the process resembles gas metal are welding. The advantage of this process is that the metal can be deposited at a faster rate with deep penetration. This process is useful where there is large volun of work in flat or horizontal a rimarily used for weldi Position only. The welds produced are strong and tough. It is primarily ing Steel, Electro-slag Welding This process is particularly suitable for welding thick pl shafts, boiler parts and heavy press. In this process, the p! Vertical position with aics and structures for turbine fates to be welded are put in a Wax coded an ‘Seating piace Electro-slag welding. Welding a gap of about 20 to 30 mm, the filler wires and the flux are kept in this gap. The filler wires are used as electrodes. Initially, an arc is struck between the electrode and the work piece. The heat of the arc melts the flux. The arc is stopped and the slag is maintained in the molten state by the resistance of the electric current passing between the electrode and work piece. The inside temperature of the molten metal rool is approximately 1950°C and the outside temperature is about 1650°C. This temperature is sufficient to melt the work piece and filler wires to form a weld after solidification ‘The molten metal pool so created is contained in the joint between the two water cooled copper shoes (dams). Since the molten metal pool is large and the welding speed is slow, therefore, the cooling rate is quite low. This results in a coarse grain size and a follow up heat treatment is normally required to restore the streugth. Electro-gas Welding The electro-gas welding is the development of electro-slag welding. In this method, either a solid electrode or a flux cored electrode is used. The elect~ des are fed automatically by a slow speed motor. The main differezce between the electro-slag welding and electro-gas, ‘welding is that in electro slag welding no flux. is fed into the joint and the heat is created by an electric are and an inert gas (carbon dioxide or argon) is fed into the joint to provide shield to the arc and the molten weld puddle. This process is used for welding work pieces £20 to 80 mm thickness in « vertical position like fabrication of ships, bridges, large tan and pressure vessels. 2 Basic Weld Symbols Sectional represenstion o ¥Y | ea |a}& } 4/2 13 Form of weld Double bevel butt Single-J bux. Double} butt Bead (edge or seal) 20. Projection Betore Ater Tne an BS = [ samees | WSS Caess| | 14 GAS WELDING Itis a type of fusi . ofa fuel gas. Ina ete welding to remove impuriti F ‘© impurities and oxides present surfac etal to and to obtain a good weld result, present on the surfaces of the metal to b The a cae aes ie s combination for producing a hot flame for welding me' rouca a titer ae ). When acetylene is mixed with pure oxygen, it bums «< acetylene flare. temperature (about 3200°C). Such a flame is known as ox; raat - The hydrogen gas or some other gas may also be used. but peratures obtained are lower than the oxy-acetylene flame. The approximate fan temperatures produced by different combination of gases are as follows: 1. Oxy-acetylene, 3200°C; 2. Oxy-hydrogen, 2400°C; 3. Oxy-propane, 2200°C; 4. Oxy-town gas, 2100°C; 5. Air-acetylene, 2400°C; 6. Air-town gas, 1800°C ; and 7. Air propane, 1750°C. Since oxy-acetylene flame is mostly used in gas welding, therefore we shall only discuss the oxy-acetylene welding in detail. Note: The oxy-hydrogen flame may be used for welding low-melting tempersrure metsis and for welding thin pieces of steel. Equipment for Oxy-acecylene Gas Welding “The basic equipment required to carry out oxy-acetylene ges welding is as follows 'A. Welding torch. The welding torch (also known as blow pipe) is @ tool for mix oxygen and acetylene in the desired volumes and burning the mixture at the end Fox noes howe coer te Me annre i= wesc 7 Sas jr % 5 e w [ a Foc ny hove (oWebtng ont. Y ee ofta tip, which produces a high temperature flame. The welding torches have a handle at one end with two inlet connections for gases. Pach inlet has valve that controls the volume Gfoxygen or of acetylene passing through them. The dest-ed proportions of oxygen and fy mixed, in the mixer, before issuing from torch to the tip or nozzle. acetylene are thorough! sae flame is produced by igniting the mixture at the torch tip, The welding torches are commercially available in the following two types; (i) Injector or low-pressure type (also known as high pressure) type. these types of torches is in the gas mixing chambers or (ii) Positive or equal-pressure ‘The principal difference between gas mixer. A gas mixing chamber must be abie; ging fr . oxygen passing a 70 to 280 kN/m2 depending upon the tip size. The high-pressure acetylene and mix with i on creates a low pressure which draws in low pressure re both gases pass into the tip. torch at Pressure type welding torch, the gases must be delivered to the on EN eenerally above 7 kN! Inthe ene of acetylene, the pressure nist be same pressure, N/m? while oxygen is generally supplied at approximately the (@) A high-pressure weldin acetylene line. () The high-pressure acetylene is usually stored in strong steel cylinders. torch should aever be connected to a low-pressure Welding torch tip. The welding torch tip {also called nozzle) is that portion of torch through which the gases Bass just prior to their ignition and burning. The tips are made of high thermal conductivity material, such as copper or copper alloy. ‘The tip size is measured by the diameter of the ceatral hole through which the gaseous mixture passes. Pressure regulators. The pressure regulators perform the following functions: a. Itreduces the source pressure (from generator, cvlinder, manifold or pipe line) to a workable pressure. b. It maintains the coastant delivery pressure and gas volumetric rate regardless of pressure variations at the source. ; c. It permits adjustment to deliver gas at a certain desired pressure within its rated pressure range. ‘The mechanical details of a regulator may differ among the different manufacturers, but the fundamental operating principles are the same for all regulators. Generally, a pressure regulator has a union nipple to attach it to the cylinder and an cutlet connection for the hose leading to the torch. There are two gauges on the body of the regulator, one showing pressure in the cylinder while the other shows pressure being supplied to the torch, ‘The working pressures are adjusted by the operator according to the requirements of the job. v and 280 KN/m? and fo, ‘he desired pressure a the welding torch for oxygen is Penvcen 70 sees tone tt is between 7 and 103 kN/m? Hose and hose fittings. The hose for welding terches should be strong, durable, non porous, light and flexible, Two lengths of hose (one for oxygen and one for acetylene) are ired (0 connect the regulator and the torch. The standard colour for oxygen hose is A and for acetylene hose is red. The special hose fittings or connections are provided for attachments (o the torch and pressure regulators. ers, The oxygen and acetylene are usually obtained from strong steel cylinders. i jers are usually Gas ey ‘which are filled by commercial suppliers of tixese gases. The oxygen cylinds {led at a pressure of 12.5 to 14 MN/n? and have capacity of 6.23 cubic metre. The mass of oxygen cylinder is approximately 66kg when it is full. The standard colour for the oxygen cylinder is black. ‘The acetylene is stored in cylinders under an initial pressure of 1S sumupheres (1.545 kN/m?) and have the capacity of 7.6 cubic metre. Its mass is about Bo ke s full, ‘The avetylene cylinders are equipped with fusible plugs at the bottom order to save the cylinder from explosion in case of fire. The standard colour for the acetylene cylinder is maroon. (b) Acetylene cylinder. J, Fusible plugs. 2. Acetylene cylinder valve, 3, Valve wrench. 4. Cylinder pressure gauge. 5. Regulator outlet pressure gauge. 6, Acetylene regulator. 7. Adjusting screw. 8. Acetylene hose to torch. 18 a ire (a) Oxygen cylinder. 1. Cap. 2. Bursting disc. 3. Oxygen valve, 4. Hand wheel. 5. Pressure gauge. 6. Oxygen regulator. 7. Adjustment screw. 8. Oxygen hose fo torch. The pure acetylene is not stable at pressures above atmospheric pressure (i.e., 103 N/m2) and may decompose explosively 6. Goggles and gloves. The goggles, fitted with coloured glasses, should be wom by the operator when welding. The gougies protect the eyes from the glare of the flam cone and molten metal. The gloves should also be worn to protect the hands. 7. Spark lighter. It provides a convenient and instant means for lighting the welding torch, ‘Welding Rods The welding rods (also called filler rods) are used in gas welding to provide extra metal to the weld by melting the end of the rod. Mostly, the composition of the welding rod material is same as that of the material being welded. In gas welding, the following types of welding rods are, usually, used. 1. For welding ferrous metals, steel rods with high carbon contents and more silicon and ‘manganese (commonly known as silicon manganese rod) are widely used. 2. For welding alloy steels, the rods containing chromium and vanadium or molybdenum are used. ms a For welding stainless steels, the rods containing titaniuia, molybdenum or niobium (commonly known as 18/8 chromiur-nickei rod) are used to prevent weld decay 4. For welding copper and its casting, drawn copper rods are use ; 5, For welding sheets of aluminium and its alloys, pure aluminium rods are used, but for aluminium castings, the rods containing upto 12 percent silicon are used. For welding magnesium alloys, the rods having sare composition as that of the material to be welded, are used. 19 rch takes place intwo | Gas Flame i ap ofa gas weldinS arbon ‘The combustion of acetylene oxygen at the tip of 295 WX AF oxygen to form oF of acetylene with puFe ONE Tene combines Wi C7) reaction OCCUTS: Stages. In the first stage, the carbon from monoxide, the hydrogen of the acetylene being bre = OF \ Inner cone outer sone (200°C) (1250°C) freed. The following © “Torch tip This reaction takes place within the inner, brilliant white cone flame, close to the iP opening. This provides the most concentrated heat with the highest temperature for welding. In the second stage the carbon monoxide and hydrogen (produced in first stage). together with oxygen from the surrounding air, form carbon dioxide and water (steam). The reaction 1 represented by the following chemical equaticn: 400 +2H,+30, = 400, +20 These reactions take place in the larger blue flame which surrounds whitish cone flame. This nner uminous cone unorbich envelope () Oxidising fame. (©) Reducing or carbonizing flame larger blue flame contributes only a preheating effect for welding. It also protects the molten metal from oxidation, The flame can be adjusted, to suit the welding conditions, by regulating the supply of acetylene and oxygen. The following three types of flames are used ior gas welding: 1. Neutral flame. This type of flame is obtsined by supplying equal volumes of oxygen and acetylene. The neutral flame has the following two sharply defined zones: (i) An inner luminous cone, and (ii) An outer cone or envelope of bluish colour. welding of steel, cast iron, copper, aluminum ete. ‘The most of the oxy-acetylene welding (6. done with the neutral flame. tis similar 0 (b). Ht is 2. Oxidizing flame. This type of flame is obtained where there is an excess of oxy {6 neutral flame but the inner cone is less luminous and shorter, as shown in Fig, used for welding brass and bronze. 3, Reducing or carburizing flame. This type of flame is obtained by supplying an excess of ‘acetylene. This flame has the following three zones: (i) An inner cone, (iy An intermediate cone of vhitish colour, and (i) An outer cone of blush colour. inimum, It is used for welding of flame is used where itis required to keep oxidation to * MIM. = ing materials such as h oy steels, many of the non-ferrous, molten metal, a certain all satelite. Gas Welding Technique in a gus welding (or oxy-acetylene welding), the acetylene is, first of all, turned on by using the conuol valve aes eerie itis eae with a friction spark lighter. The flame is adjusted bovsupplying the oxygen withthe oxygen control valve on the tore. The pieces fo bewslata properly prepared and positioned. The weld is started by preheating and melting a small pus ee aoe eee aal, In ease 2 welding Tod is used io provide filler meta, it should be held in the flames so that its end melts at sbout the same time as the base metal. In order to obtain Proper penetration and to produce a good weld, the tip of the torch shoul be moved with a side-to-side motion, slowly and uniformly. The usual techniques ia oxy-acerylene welding are as follows: |. Lefeward or forehand welding, ta this method, the welding torch is held in the operator's tight hand, the tip poinuing towards the ieft and the weld is made from right to left. The torch makes an angle of 60°—70° with the plate and the welding rod makes an angle of 300 400. The flame is given a circular, rotational or side-to-side motion to obtain uniform fusion on each side of the plate. This method is more efficient for butt welding on plates up to 2 mm thickness. 2. Right-ward or back-hand welding. In this method, the welding torch is held in the right hand and the filler rod in the left hand. The welding begins at the left hand end of the joint and proceeds towards the right. The filler rod is given circular motion while the welding torch moves in straight line. In this case, the torch makes an angle of 40°—S0° with the plate and the welding rod makes an engle of 30°— 40°. This method is better and economical for plates over 6 mm thickness. 22 3. Vertical welding. The vertical welding, left-ward technique or by the right-ward technique. The great advantage of the vertical welding is that the plate edge preparation is not required up to 16 mm thickness. In vertical welding for plates above 5 mm thickness, two operators are required. These operators use the identical welding torches, same nozzle size, pressure settings, angies of welding torch and rod, speed of travel ete The fusion is more easily achieved by this process, particularly when the two operators are employed. as shown in Fig. 15.33, may be carried out either by the Vertical welding. 4. Linde welding. It is a special welding technique which is basically used for butt welding of stee! tubes at a right-ward technique temperature below the melting point of the parent metal. In this method, the use of oxy-acetylene flame with excess acetylene is made and the right-ward technique is used, BRAZING ‘The brazing process can be defined as the process to join two metal pieces heated to suitable temperatures by using a filler metal having a liquidus above 427°C and below the solidus of the base metals. The filler metal is distributed between the closely: fitted surfaces of the joint by “capillary attraction” During brazing, the base metal of the two pieces to be joined is nut melted. Some diffusion or alloying of the filler metal with the base metal takes place even though the metal does not reach its solidus temperature. The greater the degree of adhesion and inter-diffusion between the molten filler metal and the base metals, the higher the mechanical strength o* the joint will be. To achieve this and to obtain a strong joint, the basic requirement is that the filler metal must thoroughly wet the base metal surfaces. Therefore, the surfaces must be cleaned and free of contaminants that would prevent adhesion. Thus the scale is removed by mechanica] (with a steel wire brush or emery cloth) or chemical (pickling in acids) means and heavy oily residues (oil, grease, paint ete.) are removed by degreasing witi: hot alkaline solutions or organic solvents. Again, when the assembly is heated to melt the filler metal, oxides my form which will prevent wetting of the surfaces by the molten filler metal. 24 © overcome by small am ; ‘unt of filler metal is needed to fill the joint completely. which shows the Various ways of placing the filler metal a the joint ia bo be Fluxes. Fluxes are used to prevent oxidation of the base metal and the filler metal during brazing, form a fusible slag of any oxides which may be present or formed, and promote the free flowing of the filler metal by capillary attraction. The requirements of a good flux are: 1. avpwpy It melts at a low enough temperature to prevent oxidation of the base metals and the filler materials. Ithas a low viscosity so that it is replaced by the molten filler metal. It may react with surfaces to facilitate wettin, It shields the joint while the filler is still liqui It is relatively easy to remove after the solidification of the filler. It lowers the surface tension of the molten filler metal and thus promotes its flow into the joint. BRAZING JOINTS ae es FS Brazing Joints. Common fluxes are compositions of borates, fluorides, chlorides, borax and boric acid in VaNOk® proportions according to specific requirements. Fluxes are used in form cof powder, paste, or slurry. Borax is used as fused borax, because water in it will cause bubbling during heating - Aleohol can be mixed with fused borax to form a paste. Most fluxes ate corrosive and the residue should be resolved from the work after the brazing is completed. Filler Materials. The filler metai or the braze metal must: ! 1. wet the surfaces of the base metals at the joint. 2. have high fluidity to penetrate crevices. For capillacy attraction to exist, the clearance between the parts being joined must be quite small (0.03 to 0.05 mm), otherwise the filler ‘metal would run out of the joint. A wider clearance in a joint leads to its reduced strength. 3. Preferably have a narrow melting range 4. Not lead to galvanic corrosion during service. ‘The filler metal is applied in the form of wire, strip, preforms, powder or paste to the joint area as noted above in step (iii) under “steps in brazing”. itematively, the filler metal is pre-applied to the surface of one of the contacting parts as a coating or cladding, often by rolling, electrolytic deposition or hot dipping. ‘Brazing methods. Depending upon the heat sourc> used to melt the brazing metal, the various brazing methods are given below LL. Torch brazing. A joining process that may employ acetylene, natural gas, butane oF Propane io combination with air or oxygen to supply the heat required wo melt the filer od aod 10 owe i into the surface of the base metal. This technique ts not extensively used for cant auous mass production, Flux used isin the form of paste ov powder. 2, Fumace brazing. This is a high production process where ie beat is supplied by gas or create beating coils. The fumaces are of Bex type (batch type) or continuons Gyre The fatter employs a wire mesh belt to t-ansport the parts 1 be brazed. In this process, preformed shapes of filler metal be placed on the Paris to be joined prior to entering the 26 nace. The process is well swert almosphere is maintain lnduction brazing. Here heated by placing within the fe eudy currents because the parts to ke joined changing induction fi cld. Heating is the heat can be appli Heating is very rapid, in the loc echanised. Flux is the Focal area of cd ti, In the molten metal bath process, into a molten bath of filer metal ine assembled parts are first prefluxed and then immersed The first method is an to small parts. Ne Adaptable for joining large parts, whereas the latter method is restricted 5. Resistance a filler met brazing. Here, the same equipment is used as for resistance welding, exceptin: g that metal is placed in the joint, Rapid heating minimizes oxidatioa and the heat affected zone (AZ) is small. 6. Laser brazing and electron beam brazing. These high-cost techniques are justified only for precision work of high value and relatively high-temperature materials. Only the first four brazing methods are of industrial importance. BRAZE WELDING. It differs from the conventional brazing in that much wider gap is filled with brazing brass with the help of torch. Here, capillary action plays part in making the joint. The technique is also used for the repair of iron and stee! castings. The grooves and fillets can also he filled by using bronze rods and then the process can he called as “Bronze welding”. The method is particularly useful for repairing cast iron castings. Straight welding of the casting requires its complete preheating, which is not always desirable or feasible. The brasses and bronzes have greater strength and ductility than cast iron and form a strong and satisfactory bond with the base metal. Since the base metal is not fused or highly heated, internal sizesses are kept to a minimum and cracking is not likely upon cooling. Silver brazing. When silver alloys are used for brazing, the method is called as Silver brazing’ which is often referred to as “Silver Soldering” or “Hard soldering”. The method is more expensive than plain brazing because the filler metal is more expensive. The method is preferred where a superior joint is needed and where the quantity of filler metal required is small. It is very popular in small area repair work and is used widely in the electrical arid refrigeration industries. Advantages of Brazing 1. Lower temperatures are involved in brazing than in fusion welding. This minimizes distortion and allows joining at lower preheat temperature then required for fusion welding Thus, medium carbon, and high-carbon steels and Cl. which harden in the heat affected 27 ith little or no ing nay t braze welded with lit zone and may be susceptible to cracking may be brazed or serious hardening. F satisfactorily br Almost all the common engineering materials may be prepa Inaccessible joint areas which could not be made hy MIG or ‘TIG scam welding can be formed by brazing. ing can be 4. Thin-walled tubes and light, gauge sheer metal assemblies not joinable by welding Joined by brazing. carbon steels to allo; Brazing can join dissimilar metals such as brass to stainless stesIs and carbon steels to alloy steels, Multiple joints can be made at one time, as in furnace brazing. Can be employed for joints which may have to he later disassembled. Neat appearing joint requiring a mininsum of cleaning, Lhe Process can be done more quickly and more economically 10. Many brazing operations can be mechanised. 1. Because of lower temperatures involved as compared to fusion welding, metallurgical damage to the base metal may be avoided. Limitations: azed or braze welded, rocesses, and spot or ene ° 1. Limited size of parts. Very large assemblies, aithough bravable, can be made more economically by welding because of the cost and availability cf large equipment such as brazing furnaces. 2. Machining of the joint edges for getting the desired fit is costly. 3. Degree of skill required to perform the brazing operations is high. USES OF BRAZING. Assembly of pipes to fittings, carbide tips to tools, radiators, heat exchangers, electrical parts and repeir of castings. Leak-'ight joints for pressurized and vacuum systems are readily joined by brazing. The copper-brazed joints in stee! and the nickel-alloy-brazed Joints in stainless steels are made for high-temperature service. Corrosion resistance can be provided for in food-service equipment which employs silver-brazing alloys for joining stainless steels. The chemical industry uses nickel alloy brazing for brazing stainless steels subject to corrosive service. SOLDERING. In soldering, two parts are joined by the use ofa molten filler metal whose melting point is below the solidus (melting point of the base metals) and in all cases below 427°C. Soldered joints are weaker than brazed joints. Because of lower working temperatures, good wetting is more critical than in brazing. The soldering process comprises the same steps as the brazing process, that is, reparati ich i c ing them Surface ion which invofVes fitting the surfaces to each other, cleaning co panieally and chemically and covering the cleanea surfaces witha flux. The clearance in 8 joint is about 0.05 to 0.20 mm (for steel). (ii) After this, soldering proper is done, Commonly used soldering joints are: Lap, butt, seam and pipe joints. 28 Idering are: are: Zine chlori «Ng ate; corrosive = off after sol ride, mixtures of zine caiiaes Toh-corrosive type. The common corrosive fluxes alcohol. srigering 10 prevent comosi © and ammonium chloridc. The flux must be washed Skool, These are essential for seen, Common Ron corrosive fluxes are rosin and rosin plus s ce and even loss. of conduction" Connections where corrosion can create local high The most wi " some other tly Used solders are allo metals may be added. Th 63/37 Tin-lead /37 Tin-lead solder has the lowest meltiag poi ‘ai Ttis Most suitable for electrical ee point and solidifies at a constant temperature. Ys of tin and lead in varivus proportions. Small quantities of ese filler metals used in soldering are called “Soft solders”. 32/68 Tin lead Plumber's solder. Tin-lead-silver solder : High temperature electrical soider for inscruments. (Wi) 96.5/3.5 Tin-silver : High temperature electrical instrument solder. A low (<5%) tin content gives higher strength and is suitable for automotive radiators and lock seam cans, and tubes made of tin plate. 35/65 Tin Lead : Its wide freezing range makes it ideal as a wiping solder for the joining of copper tubes. (x) Lead silver solders are used for higher temperature service. Ag : 1.5 to 3.5%. Certain other metals such as cadmium, bismuth and indium may be added for some specific purposes. Lead being toxic has adverse effects on the environment. Due to this, !sad free solders are being developed and are now in wider use. They are being used in connectior: with supplying drinking water and other applications. Typical examples arc Tin-silver (given above) for electronics. Tin-Bismuth (42%, 58%) : for electronics. Tin-zine alloys with 9 to 100%. Zine for soldering of aluminum in. conjunction with special fluxes. 4. Zinc-aluminum: for corrosion resistance, soldering of aluminum. 5. Cadmium-silver: for strength at high temperatures. SOLDERING TECHNIQUES ype The various techniques used for brazing can also be employed for soldering (flame, hot dip, resistance, induction). Ultrasonic so‘dering (similar to ultrasonic welding) is used for fluxless soldering of aluminum and some nonferrous metals such as silicon and germanium. 29

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