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Flux: it is cleaning agent used to prevent oxidation of metals at the soldering point. It helps the
solder to melt quickly and allows it to flow freely to unite more firmly.
E.g. zinc chloride, ammonium chloride, hydrochloric acid, borax, rosin, turpentine oil etc.
Solder: generally it is an alloy of lead and tin. It melts at low temperature. For strong joints a
mixture of copper and zinc is used which has high melting point.
Classification of solder:
Soft solder: for high joints using various proportions of lead and tin which has low melting point.
Hard solder: for strong joints using a mixture of copper, zinc etc. which has high melting point.
Soft solder: generally it is composed of lead and tin. They are mixed in various proportions to
solder different metals at different temperatures. The range of melting point for such solder lies
between 150 to 300C. A suitable flux for the particular job is chosen. A small amount of bismuth
and cadmium are frequently added to lower the melting point if necessary. Soft solders are used to
join the wires and sheet metal works of light jobs which are subjected to light loads and slight
shocks. A plain soldering iron is used to heat the metal pieces during the process. Soldering using
soft solder is known as soft soldering.
Hard solder: generally it is composed of copper and zinc in 4:1 ratio. A small amount of silver or
tin and antimony are frequently added to improve the quality. The range of melting point of such
solder are lies between 350 to 900C.the fixtures for such solder will be in paste form. A propane
torch is used to heat the metal pieces during the process. Hard solders are used to make
comparatively strong joints compare to soft solder. e.g.: plumbing, heavy sheet metal works etc.
4.5.1
Method of soldering:
The step by step general procedure for soldering is as follows:
The metal parts which are to be soldered must be thoroughly cleaned.
The type of job whether light or heavy has to be decided.
A good soldering iron has to be selected.
In case of light jobs, the tip of the heating head of the soldering iron has to be heated
sufficiently.
It has to be then cleaned, dipped in flux and the rubbed on the solder to tin the tip.
The molten solder has to be then deposited on the joint.
In case of heavy jobs, the surface must be tinned first by cleaning, the heating using a blow
torch.
The job must be dipped in flux.
Using a solder iron, the solder has to be applied over the parts.
The parts may be then assembled and heated together until the solder melts.
In case corrosive flux is used, the soldered job must be washed with water.
Advantages of soldering:
It is simple and economical.
Base metals are safe against the metallurgical damages due to low operating
temperature.
2.Brazing:
It is the process of uniting two or more metals of similar or dissimilar type with the help of an alloy
in the form of spelter and flux, like borax, ash etc. these are used in tanks, radiators, carbide tips on
tool holder etc.
Types of brazing:
It is classified on the basis of actual heating as:-
Torch brazing
Electric brazing
Immersion brazing.
Method of brazing:
The step by step procedure for brazing is as follows:
The metal parts which are to be brazed must be thoroughly cleaned.
The flux must be applied to the surface.
The parts are to be clamped in the required position.
The flux ha to be applied on the surfaces.
The job has to be heated using the blow torch or the furnace etc.
The molten spelter has to be allowed to flow by capillary action into the joint.
The job has to be allowed to cool slowly.
4.5.2
Advantages:
Even dissimilar metal pieces can be united.
No metallurgical damage to base metals.
Provides stronger joints than hard soldering.
BECAUSE OF THE LOWER TEMPERATURES USED THERE IS LESS DISTORTION IN BRAZED JOINTS. ALSO, IN MANY CASES
THE ORIGINAL HEAT TREATMENT OF THE PLATES BEING JOINED IS NOT AFFECTED BY THE BRAZING HEAT. THE JOINT
CAN BE QUICKLY FINISHED WITHOUT MUCH SKILL. BECAUSE OF THE SIMPLICITY OF THE PROCESS IT IS OFTEN AN
ECONOMICAL JOINING METHOD WITH REASONABLE JOINT STRENGTH. THE BRAZED JOINTS ARE REASONABLY
STRONGER, DEPENDING ON THE STRENGTH OF THE FILLER METAL USED.
SILVER BRAZING MAKES USE OF A SILVER BASED FILLER METAL. SILVER BRAZING IS USED TO GIVE HIGH STRENGTH
JOINTS. THOUGH ORIGINALLY USED FOR JEWELLERY APPLICATIONS, SILVER BRAZING IS NOW EXTENSIVELY USED IN
INDUSTRIAL APPLICATIONS. THEY CAN BE USED WITH A LARGE RANGE OF MATERIALS, BUT BECAUSE OF ITS HIGH COST
IT IS USED IN ONLY SPECIAL APPLICATIONS REQUIRING HIGH STRENGTH AND HIGH TEMPERATURE SERVICE.
Applications
Brazing Is A Much Widely Used Joining Process In Various Industries Because Of Its Many Advantages. Dissimilar Metals,
Such As Stainless Steel To Cast Iron Can Be Joined By Brazing. Almost All Metals Can Be Joined By Brazing Except Aluminum
And Magnesium Which Cannot Easily Be Joined By Brazing.
Brazing
Spelter is used in this process.
Joints are very strong.
Costs more.
4.5.3
3. Welding
Welding may be define das the metallurgical joining of two metal pieces together
to produce essentially a single piece of a metal. Welding is extensively used in
fabrication work in which metal plates, rolledsteelsections, casting of ferrous
materials are joined together. It is also used for repairing broken, worn out, or
defective metal parts.
Principle of welding:
A welding is a metallurgical process in which the junction of the two parts to be joined are
heated and then fused together with or without application of pressure to produce a continuity of the
homogeneous material of the same composition and characteristics of the parts which are being
joined.
Types of welding:
Pressure welding: -In this the parts are to be joined are heated only up to the plastic state and then
fused together by applying external pressure.
Fusion welding:-In this the joint of two parts is heated to the molten state and allowed to solidify.
The different types of fusion welding are
Arc welding
Gas welding
4.5.4
4.5.5
4.5.6
Carburizing Flame:
This is a flame in which an excess of acetylene is burning, i.e. combustion is incomplete and
unconsumed carbon is present. Towards the blowpipe an inner white cone of great luminosity
appears. The carburizing flame which is mainly used for hard surfacing and should not be
employed for welding steel as unconsumed carbon may be introduced into the weld and produce a
hard, brittle, deposit.
Neutral Flame:
As the supply of oxygen to the blowpipe is further increased, the flame contracts and the white cone
become clearly defined, assuming a definite rounded shape. At this stage approximately equal
quantities of acetylene and oxygen are being used and combustion is complete, all the carbon
supplied by the acetylene is being consumed and the maximum heat given out. The flame is now
neutral, and this type of flame is the one most extensively used by the welder, who should make
himself thoroughly familiar with its appearance and characteristics.
Oxidising Flame:
A further increase in the oxygen supply will produce an oxidising flame in which there is more
oxygen than is required for complete combustion. The inner cone will become shorter and sharper,
the flame will turn a deeper purple color and emit a characteristic slight "hiss", while the molten
metal will be less fluid and tranquil during welding and excessive sparking will occur. An oxidising
flame is only used for special applications, and should never be used for welding.
Welding defects:
Common weld defects include:
i. Lack of fusion
ii. Lack of penetration or excess penetration
iii. Porosity
iv. Inclusions
v. Cracking
vi. Undercut
vii. Lamellar tearing
Any of these defects are potentially disastrous as they can all give rise to high stress intensities
which may result in sudden unexpected failure below the design load or in the case of cyclic
loading, failure after fewer load cycles than predicted.
4.5.7