JOINING PROCESSES:

SOLDERING, BRAZING & WELDING

INTRODUCTION
Some products cannot be manufactured as a single piece. The desired shape and size of such
products can be obtained by joining two parts of same or different materials. These parts are
manufactured individually and are joined together to obtain the desired product. For example,
air craft and ship bodies, welded machine frames, furniture, computers, bridges and the
transmission or electric towers etc., are all fabricated by joining several different parts.

Based on the type of joint produced joining processes can be classified as

1. Temporary Joint.
2. Permanent Joint.

If a product is in use for a long time and there is wear and tear, the parts need to be dismantled
for maintenance, repair or replacement. A temporary joint can be easily dismantled separating
the original parts without any damage to them. In case it is a permanent joint, an attempt to
separate the parts already joined will result in the damage of the parts. In a permanent joint, the
joint is made such that it has properties similar to the base metal of the two parts. The joined
parts become one piece. These parts cannot be separated into their original shape, size and
surface finish. Based on the process used for making the joint, the joining processes can be
further classified as

1. Soldering.
2. Brazing.
3. Welding.
4. Mechanical Fasteners like bolts, nuts, rivets, screws etc. (not in syllabus)
5. Adhesive bonding. (not in syllabus)

Mechanical fasteners are most widely used for temporary joints. Joints obtained by bolts and
screws are temporary in nature and can be dismantled easily whenever necessary. Rivets are
semi-permanent fastening devices and the joint can be separated only by destroying the rivet
without affecting the parent elements. Adhesive bonding has generally less strength than the
mechanical fasteners. But adhesive bonding is used to join odd shaped parts or thin sheets
which may not lend themselves to mechanical fastening. Brazing and soldering are considered
to form permanent joints, but for repair or replacement these joints can be dismantled by
heating. Welding is one of the most extensively used fabrication method. The joint strength
obtained in welding is being equal to or some times more than that of the parent metal. Welding
is not only used for making structures, but also for repair work such as the joining of broken
castings. The choice of a particular joining process depends on several factors such as
application, nature of loads or stresses, joint design, materials involved and size and shape of
the components.
SOLDERING
Soldering is a method of joining similar or dissimilar metals by the application of heat and
using a filler metal or alloy called solder, whose liquidus temperature is below 4500 C. The
molten filler metal is made to flow between the two closely placed adjacent surfaces by the
capillary action.

Though soldering obtains a good joint between the two plates, the strength of the joint is limited
by the strength of the filler metal used. Soldering is used for obtaining a leak proof joint or a
low resistance electrical joint. The soldered joints are not suitable for high temperature
applications because of the low melting temperatures of the filler metals used.

The purpose of using the flux is to prevent the formation of oxides on the metal surface when
the same is heated. The fluxes are available in the form of powder, paste, liquid or in the form
of core in the solder metal. It is necessary that the flux should remain in the liquid form at the
soldering temperature and be reactive to be of proper use. The filler metals used are essentially
alloys of lead and tin. The composition of solder used for different purposes are as given below
Soft solder - lead 37% tin 63%

Medium solder - lead 50% tin 50%

Plumber’s solder - lead 70% tin 30%
Electrician’s solder - lead 58% tin 42%

Soldering is classified into soft soldering and hard soldering. Soft soldering is used extensively
in sheet metal work for joining parts that are not exposed to the action of high temperatures
and are not subjected to excessive loads and forces or vibrations. Soft soldering is also
employed for joining wires and small parts. The solder is mostly composed of lead and tin. In
soft soldering, Zinc chloride and ammonium chloride are the most common soldering fluxes
used which are quick acting and produce efficient joints. But because of their corrosive nature
the joint should thoroughly cleaned of the entire flux residue from the joint. These are to be
used only for non-electrical soldering work. Rosin and rosin plus alcohol based fluxes are least
active type and are generally used for electrical soldering work.

Hard soldering employs solder which melts at higher temperatures (3500 C to 9000 C) is
stronger than used in soft soldering. Hard solder is an alloy of copper and zinc to which silver
is added some times. German silver, used as a hard solder for steel is an alloy of copper, zinc
and nickel.

Sequence of operations:
The following operations are required to be performed sequentially for making soldered joints.
1. Shaping and fitting of metal parts together: The two parts to be joined are shaped to fit
closely so that the space between them is extremely small and filled completely with
solder by capillary action. If a large gap is present, capillary action will not take place
and the joint will not be strong.
2. Cleaning of surfaces: In order to obtain a sound joint, the surfaces to be soldered are
cleaned to remove dirt grease or any other foreign material.
3. Application of flux: The flux is applied when the parts are ready for joining.
 4. Application of heat and solder: The parts are held in a vice or with special work holding
devices so that parts do not move while soldering.
5.
Advantages:
1. Simple and economical process.
2. Relatively low temperature process, there is no metallurgical damage to base metal.
3. The soft soldered joints can easily be dismantled by simple heating.

Disadvantage:
1. The strength of joint relatively low.
2. Flux must be thoroughly cleaned off after soldering, as it is often corrosive.

BRAZING

Brazing is a process of making joints where in coalescence is produced by heating to suitable

temperatures above 5000 C and by using a non-ferrous filler metal having a melting point (up
to 9000 C) below that of the base metal, the filler metal being distributed between the closely
fitted surfaces of the joint by capillary action. Brazing gives a much stronger joint than
soldering.

The principal difference is the use of a harder filler material commercially known as spelter.
Filler metals used in this process may be divided into copper base alloys and silver base alloys.
The spelter is usually an alloy of copper, zinc and tin. Both similar and dissimilar metals can
be joined. The flux along with spelter (filler metal) is applied to remove oxides from the
surfaces. Borax is the most widely used flux. It will dissolve the oxides of most of the common
metals. Other fluxes used are mixtures of borax, boric acid, fluorides and chlorides.

Advantages:
1. Dissimilar metals, such as stainless steel to cast iron can be joined by brazing. Almost
all metals can be joined by brazing except aluminium and magnesium which cannot
easily be joined by brazing.
2. Because of the lower temperatures used there is less problems due to heat.
3. The joint can be quickly finished without much skill.
4. Because of the simplicity of the process it is often an economical joining method with
reasonable joint strength.
5. The brazed joints are reasonably stronger, depending on the strength of the filler metal
used.
Disadvantages:
1. Flux material required to prevent the corrosion.
2. Large section cannot be joined.
3. Fluxes and filler materials may toxic
Applications of Brazing:

Brazing has been used to manufacture a wide variety of products such as Honey comb
sandwich panels for aircraft missiles, motor cycle frames, air plane propellers, Hydraulic
fitting, refrigerator evaporators, manufacture of cutting tools etc.,

The use of pressure-vacuum brazing has found wide spread acceptance in the general
application of brazing joint in nuclear, aerospace engineering.

WELDING
Welding is a process of metallurgically joining two pieces of metals by the application of heat
with or without the application of pressure and addition of filler metal.

The joint formed is a permanent joint. Modern methods of welding may be classified under
two broad headings.
a. Plastic welding process
b. Fusion welding process

In plastic welding process the pieces of metal to be joined are heated to a plastic state and then
forced together by external pressure. This procedure is used in forge welding, resistance
welding, spot welding in which pressure is required.

In the fusion welding, the material at the joint is heated to a molten state and allowed to solidify.
This includes gas welding arc welding and Thermit welding.

The surfaces of the metal which are to be joined by any of the welding processes must be
sufficiently clean to permit clean metallic surfaces to come in to contact. In some operations,
materials known as fluxes are applied to the parts being welded to dissolve the oxides or to
prevent the formation of oxides. Fluxes are different for different metals. For ferrous materials
borax, sodium carbonate etc, have been found to give excellent results.

Types of Joints:
The welding joints are classified as Butt, Lap, Tee, Corner joints and edge joints. The choice
of the type of joint is governed by the kind of metal to be welded, its thickness and technique
of welding. Figure 4.6 shows the different types of joints used in welding
ARC WELDING:
Arc welding is a method of joining metals with heat produced by an electrical arc. In this
process the heat necessary to melt the edges of the metal to be joined is obtained from an
electric are struck between the electrode (filler rod) and the work, producing a temperature of
40000C, in the welding zone. The heat of the arc melts the base metal or edges of the parts
fusing them together. Filler metal, usually added melts and mixes with molten base metal to
form the weld metal. The weld metal cools and solidifies to form the weld. In most cases, the
composition of the filler material, known as welding rod, needed to provide extra metal to the
weld, is same as that of the material being welded.

A typical arc welding setup is

shown in Figure
1. An arc welding circuit consists of
a power supply to furnish electric
power.
2. An electrode to conduct the
electricity to the arc.
3. Cables which connect the power
supply to the electrode and
workpiece to complete the welding
circuit.
4. The arc itself provides the heat
for welding
5. The workpiece to weld is kept on
a metallic table

The arc must be shielded because; as it hardens the molten metal combines with oxygen and
nitrogen to form impurities that weaken the weld. Shielding can be obtained by adding a paste,
powder or fibrous flux to the arc. The electrodes are usually coated with a flux. This coating
forms a gaseous cloud that shields the molten metal from the atmosphere. The coating also
forms a protective slag. The slag floats on the molten pool and hardens as the weld cools. This
keeps impurities out of the weld. The process is shown in Figure.
Advantages:
1. As a manual process it is applicable to an infinite variety of work and can be executed
in any position.
2. There is less buckling and warping of the work.
3. It produces strong sound and ductile welds.
4. Satisfactory welds can be produced in heavy as well as in light sections.
5. Low cost process.
6. Excellent joint properties can be obtained in mild, low alloy and stainless steels, nickel
and copper-base alloys.
7. Low accuracy in setting up required.
Disadvantages:
1. Basically a manual process requiring adequate operator skill for good results.
2. Electrodes require frequent changing.
3. Multi run welds necessary on thick plate-slag chipping necessary after each run.
4. The principal disadvantage has been the high heat of the metal arc which makes it
unsuitable for use on materials less than 1.55 mm thick.
5. High initial cost of welding equipment.

Gas welding

Gas welding is a fusion welding process, in which a flame produced by the combustion of gases
is employed to melt the metal. The molten metal is allowed to flow together thus forming a
solid continuous joint upon cooling. By burning pure oxygen in combination with other gases,
in special torches, a flame upto 33000 C can be attained. The gas is purchased in cylinder and
connected through resulting valves and pressure gauges into flexible hoses attached to the
nozzle. A typical arrangement is shown in Figure
The oxy-acetylene flame is used to pre heat the parts to be welded around the joint and also to
melt the filler metal. A jet of oxy acetylene flame issuing from the nozzle of a burner is played
on the junction of the two pieces to be welded. At the same time a filler rod is held in the zone
of jet and its melt is deposited on the fused junction. A weld is obtained after the molten metal
solidifies. The coating on the filler rod acts as a flux to keep the joint clean. The filler metal or
filler rod used must combine with the parts being joined. The melting point of the filler metal
must be the same or lower than the melting point of the metal being joined.

Neutral Flame:

The correct adjustment of the flame is very important for reliable works. When oxygen and
acetylene are supplied to the torch in nearly equal volumes, a neutral flame is produced having
a maximum temperature of 32000C. This neutral flame is desired for most welding operations.
Neutral flame has little effect on the base metal and sound welds are produced when compared
to other flames. Figure shows neutral flame.

Carbonizing Flame:

In a carbonizing flame or reducing flame excess of acetylene is present. The temperature of

this flame is low. The excess unburnt carbon is absorbed in ferrous metals, making the weld
hard and brittle. In between the outer blue flame and inner white cone, an intermediate flame
feather exists, which is reddish in colour. The length of the flame feather is an indication of the
excess acetylene present. Figure shows a carbonizing flame. Carbonizing flame is used for
welding high carbon steels and cast iron, alloy steel and for hard facing.
Oxidizing Flame:

In an oxidizing flame excess of oxygen is present. The flame is similar to the neutral flame
with the exception that the inner white cone is some what small, giving rise to higher tip
temperatures. Excess of oxygen in the oxidizing flame causes the metal to burn or oxidize
quickly. Oxidizing flame is useful for welding some nonferrous alloys such as copper and zinc
base alloys. The Figure shows the oxidizing flame.

Advantages:
1. The equipment is in expensive in complicated and it is easily portable.
2. Useful for welding light metals such as automobile bodies and repair works.
3. A large variety of material can be welded.
4. Welds can be produced at reasonable cost.
5. Compared to electric arc welding this provides greater flexibility with respect to heat
impact and cooling rates.
Disadvantages:
1. Gas welding equipment must always be handled carefully as in certain circumstances
acetylene is explosive (when a flame is applied under pressure) as oxygen when used
in an oily atmosphere (such as an olds dirty garage floor pit).
2. A high temperature flame from a hand held torch is dangerous when handled carelessly.
3. It is much slower than electric arc welding and does not concentrate the heat close to
the weld. Thus, the heat treated area is larger, which causes more distortion.
4. Highly skilled operators are required to produce a good weld.
5. If electric arc welding is available gas welding is seldom used for work over 3.2mm thick.
6. The process is not sa sfactory for heavy sec on.
Difference between welding, brazing and soldering
Brazing Soldering Welding
In brazing filler metal is Soldering using the filler Welding using the filler
having the melting point metal having the melting metal having the melting
greater than 450ºC point less than 450ºC point nearly equal to the base
metal
Joints takes place due to Capillary action is also No capillary action is
capillary actionbetween the present in soldering between present. Joint takes place due
base metaland the filler metal the base metal and filler to fusion.
metal.
Base metal does not melt Base metal does not melt. Base metal melts in welding
Filler metal is having the Filler metal is having the In welding filler metal is not
melting point less than the melting point less than the having the melting point less
base metal. base metal. than the base metal.
Filler metal is uniformly Filler metal is uniformly Filler metal melts and gets
distributedbecause of distributed because of mixed with the base metal
capillaryaction. capillary action
Joints are stronger than Joints are weaker than Joints are stronger as
soldering but weaker than brazing compared to brazing,
welding Soldering
It was uses filler metal It uses the filler metal which It uses the filler metal mostly
which contains copper contains lead and tin. having the same composition
and zinc etc. as that of base metal.
Tungsten Inert Gas(TIG) Welding:

 In this operation, the work pieces to be joined are cleaned to remove dirt,
grease and other oxideschemically or mechanically to obtain a sound weld.
 The welding current and inert gas supply are turned ON.
 An arc is struck by touching the tip of the tungsten electrode with the work piece,
and instantaneously the electrode is separated from the work piece by a small
distance of 1.5-3 mm such that the arc still remains between the electrode and the
work piece.
 The high intensity of the arc melts the work piece metal forming a small molten
metal pool. iller metal in the form of a rod is added manually to the front end of
the weld pool.
 The deposited iller metal ills and bonds the joint to form a single piece of metal.
 The arc is extinguished by widening the gap between the workpiece and the
electrode.
 The shielding gas is allowed to imping on the solidifying weld pool for a few
seconds even after the arc is extinguished.
 This will avoid atmospheric contamination of the solidifying metal thereby
increasing the strength of the joint.
 Advantages:
1. Suitable for the thin metals
2. Clear visibility of the arc provides the operator to have a greater control over the
weld
3. Strong and high quality joints are obtained
4. No lux is used. Hence, no slag formation. This results in clean weld joints.

Disadvantages:
1. TIG is the most dif icult process compared to all the other welding processes.
2. Skilled operator is required
3. Process is slower
4. Not suitable for thick metals.



Metal Inert Gas (MIG) Welding:

 In this operation, the workpieces to be joined are cleaned to remove dust,

gease and other oxides,chemically or mechanically to obtain a sound weld.
The tip of the electrode is also cleaned with a wire brush.
 The control switch provided in the welding torch is switched ON to
 initiate the electric power,shielding gas and the wire (electrode) feed.
 An arc is struck by touching the tip of the electrode with the work piece, and
instantaneously the electrode is separated from the work piece by a small
distance of 1.5-3 mm such that the arc stillremains between the electrode and
the work piece.
 The high intensity of the arc melts the work piece metal forming a small molten
pool.
 At the same time, the tip of the electrode also melts and combines with the
molten metal of the workpieces there by illing the gap between the two work
pieces.
 The deposited metal upon solidi ication bonds the joint to form a single piece of
metal.

Advantages:
1. MIG welding is fast and economical
2. The electrode and inert gas are automatically fed. This reduces the burden on the
operator, and alsohelps him to concentrate on the arc.
3. Weld deposition rate is high due to the continuous wire feed.
4. No lux is used. Hence, no slag formation. This results in clean welds
5. Thin and thick metals can be welded.
6. Process can be automated.

Disadvantages:
1. Equipment is costlier
2. Dross and porosity are the most prevalent quality problems in this process.
However, extensive edge preparation can be eliminate this defect.