Training Unit
No: WE 026
Training Unit
Soldering and Brazing
Theoretical and Practical Part
No.: WE 026
Edition:
2008
All Rights Reserved
Editor:
CONTENTS
1
SOLDERING ................................................................................................................4
1.1
1.1.2
1.2.1
1.2.2
1.2.3
1.2.4
1.2.5
1.2.6
2.2
2.3
Fluxes ................................................................................................................18
2.4
BRAZE WELDING......................................................................................................21
3.1
Hard soldering......................................................................................................4
1.1.1
1.2
Page
Butt-welds ..........................................................................................................23
4.1.1
4.1.2
4.1.3
4.1.4
Lateral notches...............................................................................................25
4.1.5
4.1.6
4.1.7
4.1.8
4.1.9
4.1.10
4.1.11
Pipe misalignment......................................................................................28
4.1.12
4.2
Sagged root....................................................................................................27
4.2.1
4.2.2
Lateral notches...............................................................................................29
4.2.3
Fusion faults...................................................................................................30
PRACTICAL PART.....................................................................................................31
Instructions for practical exercise 1 - Soldering Exercise...............................................31
Instructions for practical exercise 2 - Bending Sample ..................................................33
Bending Sample.............................................................................................................34
Braze weld copper to steel exercise:3 ...........................................................................35
SOLDERING
Soldering means the joining of metals using separate metals (solders) which have
melting points below those of the parent materials.
1.1
Hard soldering
Sources of heat:
Acetylene-oxygen flame, propane gas, town coal gas, hydrogen and natural gas.
Soldering:
-
Diffusion
material brass
diffusion layer
alloy layer
solder
alloy layer
diffusion layer
material steel
Scale 1:2000
Advantages:
-
In this way, an even and clean soldered joint is made which generally requires no
mechanical treatment (milling etc.) afterwards.
good
bad
good
bad
Caution:
Solder gap width must be at least 0.05 mm and at most 0.2 mm.
1.1.1
Application:
Soldering carbide tips onto tools.
1.1.2
1.1.2.1 Purpose
Flux prevents access of air at the place being soldered and thereby inhibits oxidation.
Caution:
Use flux suited to the solder. Avoid overheating the material being soldered and avoid
overheating the flux.
Soldering times should be as short as possible, otherwise oxidation may occur.
Remove flux residue.
If the shape of the piece to be soldered makes it possible to remove the flux entirely,
neutral (non-corrosive) fluxes must be used.
1.2
Soft soldering
1.2.1
Sources of heat
These include:
Electricity, gas flame, forge, petrol blowlamp.
1.2.2
Soldering tools
Application:
Mainly for spot soldering and internal soldering.
Application:
Mainly for soldered joints on sheet metal.
Both types of soldering iron are of simple design and can only be used for a short time,
because they cool off rapidly.
The heat needed for the soldering process is stored in the copper body of the soldering
iron. Copper absorbs heat well and releases it quickly to the place being soldered.
The surface must be metallically clean. Heat the soldering iron. As soon as the solder
runs tin the point of the soldering iron using flux and a rag.
Wipe away excess solder.
The soldering iron face may be tinned with sal ammoniac stone with the addition of
solder.
solder
10
heating element
handle
11
1.2.3
Soft solders
Distinctions are made between soft solders according to their alloy components:
Examples:
Lead-tin solders
and
Tin-lead solders
75 Pb + 25 Sn
60 Sn + 40 Pb
60 Pb + 40 Sn
90 Sn + 10 Pb
Eutectic solder:
68 Sn + 32 Pb
This has the lowest melting point of 182 C. At this temperature the solder becomes fluid
immediately (no pasty stage).
All other solders have an incipient pasty stage.
Soft solders for heavy metals are mainly tin-lead alloys.
For soldering on electrical equipment, resin-cored solder is generally used.
There are standard symbols for pipe solder, e.g.,
LSn 50 Pb = 50% Sn + 50% Pb, melting point 210 C
LSn 60 Pb = 60% Sn + 40% Pb; melting point 190 C
Plumbers solder
(cored solder)
rod solder
resin core
d=1
1.5 mm
2 mm
3 mm
tin component in %
Plumbers solder has a core made of resin (distilled pine resin) which serves as flux.
12
Melting phases:
The solder melts when heated. From a solid state it becomes first pasty and then fluid.
These solders may be called smearing solders, e.g., 33 Sn + 77 Pb = smearing solder for
wiped joints (e.g., joining lead pipes).
1.2.4
Acid fluxes:
Hydrochloric acid (dilute) for soldering zinc and galvanized sheet metal.
Sal ammoniac:
For tinning the soldering iron.
They are suitable for soldering metals which must not be exposed to the subsequent
action residues.
Caution:
Acid flux residue must be removed from the soldered joint by washing.
13
1.2.5
The joint must be meticulously clean. It can be cleaned mechanically by abrasion (file
and cloth etc.) or chemically with acids or solvents.
Apply solder to the heated soldering iron, then draw the soldering iron carefully and
slowly over the place to be soldered.
Do not loosen the fixed pieces until the solder has hardened.
1.2.6
14
nozzle
valve
liquid-gas cartridge
15
Cleaning paste (based on hydrochloric acid) is applied with a brush to the abraded
surfaces. Let the paste reach for a short time and then wash it off.
Apply tinning paste (tin and lead dust mixed with tallow and sal ammoniac mixture)
evenly to the surface being cleaned.
Both halves of the bush are heated evenly to the soldering temperature. Test the
temperature with a thermochrome stick.
Apply rod solder to the tinned surfaces of one half of the bush.
For bushes of two-thirds aluminium and one-third zinc, the solder is brushed on with a
steel brush without flux.
soldered bush
soldered joint
16
SOLDERING BRAZING
Soldering and brazing are joining processes which form semi-permanent joints. In such
processes two metal pieces are bonded at the interface with an easily meltable solder i.e.,
a partially chemical, partially mechanical union.
In soldering and brazing the surface the surfaces are heated only to the working
temperature of the bonding metal. In welding the edges and the welding wire are
heated (Melting point).
Soldering
Brazing
up to 450 C
over 450 C
Zn 419
S1 Cu F1 red 1083
Pb 327
S2 Ms F2 yellow 900
Sn 232
S3 Ns F3 green 900
Ag 550
S = welding rod
F = flux
2.1
17
deposition brazing
2.2
Brazing solders
Heat resistant brazing solders are nickel, chromium and cobalt (Palladium alloys).
Cu
pure copper
Ms60
SnBz12
Ns
CuP8
Ag40
silver-brazing solders
ALS 13
Generally available in wore or bar form in combination with a flux or pure metals. Power
forms and leaf forms may be used for specialised applications.
2.3
Fluxes
The oldest fluxing agent is dispersion borax (potash and common salt).
Because of the large variety and the different compositions of brazing solders a large
assortment of fluxes are available which are matched to the respective brazing solders.
Fluxes are used in powder form and paste form.
Note:
Fluxes must be mixed in paste form.
Aluminium flux should only be mixed with distilled water.
Prevent oxidation.
18
2.4
Guide the brazing solder along the joint with light pressure.
prepare workpiece
apply flux
brazing
solder
BRAZING
19
a)
b)
induction brazing
c)
bit soldering
(soft soldering)
soldering -stone
20
d)
BRAZING WELDING
STEEL
COPPER
BRAZE WELDING
With braze welding, preparation of the joint to be brazed is very important. Breaks in
pieces of cast iron or while malleable cast iron must be prepared so that they have a 90
Vee.
resistance brazing
Joint preparation
brazing + welding =
braze welding
21
3.1
With a copper rod, the copper is welded and the steel brazed.
copper
steel
The strength of a weld depends on the tools and fillers used, their shapes, their
arrangement on the piece to be welded and the manner in which it is made by the welder.
22
4.1
Butt-welds
23
4.1.1
Reinforced joint
4.1.2
Sagged weld
4.1.3
Poses arise as a result of incorrect application of flame and filler or where the material
welded is very dirty.
24
4.1.4
Lateral notches
Undercutting results from incorrect application of the flame and filler rod movement or
insufficient application of filler material.
4.1.5
25
4.1.6
Root faults occur when the pear-shaped aperture is not maintained during welding.
4.1.7
The root has been melted only on one side because the torch has been incorrectly held.
Root notches can also occur as a result of improper joint preparation, especially when
welding is performed without moving the item being welded.
4.1.8
Flame held too far away, torch held improperly and pear-shaped aperture in the root
disregarded these are the main causes of root fusion faults.
26
4.1.9
Sagged root
Occurs when the travel speed is too low and where torch is held at too steep an angle.
This occurs with leftward welding of sheet metal over 3 mm thick (weld flame has no
protective effect on the root side).
27
Improper joint preparation; misalignment must be corrected with heat treatment before
begins.
The fault can arise as a result of the molten pool running ahead or as a result of jerky
torch movement. Slag and pores occur as a result of dirty filler rod or parent metal.
28
4.2
4.2.1
Fillet welds
This occurs where the speed of travel is too high, insufficient filler material is applied and
the torch held at the wrong angle.
4.2.2
Lateral notches
These occur when an incorrect torch angle is used and the upper sheet metal is melted
too much.
29
4.2.3
Fusion faults
These occur when the lower run is not melted properly, when the speed of travel is too
high and the torch is held at the wrong angle.
Note:
These welding faults show that, in addition to good practical ability, extensive theoretical
knowledge is also needed in order to be able to check the suitability of materials for
welding.
30
PRACTICAL PART
1. PREVIOUS KNOWLEDGE
a)
b)
Filling.
c)
1. INSTRUCTIONS
Working procedure:
-
Deburr
Apply flux
Heat
Apply solder
a)
Safety precaution:
Make sure that the file handle is securely fixed.
b)
Sources of error:
Overheating
Faulty seams due to oil or grease residues.
31
SOLDERING EXERCISE
Exercise No.:1
Part 2
LONGITUDINAL FILED Part 1
CROSS FILED
Procedure:
1. Prepare to size
2. Deburr
3. File the parts according to instructions
4. Fit into the soldering jig
5. Apply fluxing agent (spread on solder)
6. Heat (fluxing agent must become liquid)
7. Solder along the soldering area
8. After cooling, remove flux film and clean
9. Bend test
Legend:
XXX ......... Welders ID Number
Material: M.S.
Plate dimension:
35 x 25 x 5 1Pc
35 x 20 x 4 1Pc
Filler material:
Welding gases:
C2 H2, O2
Repetition of the exercise if the result is not satisfactorily as per instructors advice.
BASIC SKILLS IN BRAZING
32
Test procedure:
As shown in drawing sheet 2. The bend test has to be done on an anvil, by using of a
hand hammer. Evaluation of the workpiece use evaluation sheet.
a)
Safety precaution:
Make sure that the file handle is securely fixed.
b)
Sources of error:
Overheating.
Faulty seams due to oil or grease residues.
33
Bending Sample
From exercise No.:1
EVALUATION OF THE BENDING SAMPLE
(5 POINTS)
Exercise No.:2
900 .. OP
FRACTURE AT ~ 700 ... 1p
1
~ 450 ... 2p
2
3
~ 300 ... 3p
5p
tearing
b)
overheating
c)
34
~150 ... 4p
welding
brazing
COPPER
STEEL
XXX
Legend:
XXX .... Welders ID Number
1.
Copper pipe:
2.
Steel pipe:
60 x 4 x 100 1Pc.
Filler material:
Remarks:
- 90 bead angle
- Soften copper, heat steel to melting temperature of copper (1083)
35