EXPERIMENT NO.

Aim:-
Demonstration on preparation of jobs using Soldering and Brazing

Introduction
Soldering is a simple and fast means for joining sheet metal, making electrical connections, and
sealing seams against leakage. Like welding, soldering uses a filler metal (commonly called
solder) to join two metals. However, unlike welding, soldering joins the two metals without
heating them to their melting points. In addition, you can also use soldering to join dissimilar
metals such as iron, nickel, lead, tin, copper, zinc, aluminum, and many other alloys. 800°F is a
key determining temperature. Because solder’s melting temperature is below 800°F, it is not
classified as a welding or brazing process. Welding and brazing usually take place above 800°F,
the one exception being lead welding, which occurs at 621°F.

Definitions:
1. Soldering:
Soldering is a process of uniting two or more metal pieces under heat with the help of a solder
and a flux. There are two types: Soft soldering and Hard soldering.
2. Flux:
It is cleaning agent used to prevent oxidation of metals at the soldering point. Most metal
surfaces form scale, rust, and oxides when exposed to air, and heating accelerates their
formation. Solder will not adhere to or wet metal with these pollutants. Fluxes are chemical
compounds you use to clean and maintain the metal surfaces during the soldering process (Fig.
5.1).
They also decrease the surface tension of the solder, making it a better wetting agent. Fluxes
are available in cake, paste, liquid, or powder form and are classified as either noncorrosive or
corrosive for situational application with specific metals.

Fig. 5.1 Flux action during soldering

Fig. 5.2 Soldering Iron

Classification of solder:
1. 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.
2. 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
solders 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.

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, then 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.

Brazing
Brazing is the process of joining metal by heating the base metal to a temperature Above 800°F
and adding a nonferrous filler metal that melts below the base metal’s Temperature.
Sometimes brazing is called hard soldering or silver soldering because the filler metals are
either hard solders or silver-based alloys.
Types of brazing:
It is classified on the basis of actual heating as:-
• Torch brazing
• Electric brazing
• Immersion brazing.
Heating Devices
The source of heat depends on the type and amount of brazing required. If you were doing
production work and the pieces were small enough, you could put them into a furnace and
braze them all at once. Alternatively, you could mount individual torches in groups for
assembly line work, or you could use an individual oxyacetylene or MAPP oxygen torch to
braze an individual item.
Filler Metals
Brazing filler metals are nonferrous metals or alloys with a melting temperature below the
base metal, but above 800°F. They must have the ability to wet and bond with the base metal,
be stable, and not be excessively volatile. The most commonly used filler metals for brazing are
the silver-based alloys available in rod, wire, powder, and preformed form.
Fluxes
Brazing requires flux to stop any oxides or similar contaminants from forming during the
process, and flux increases both the flow of the filler metal and its ability to stick to the base
metal. Flux helps form a strong joint by bringing the filler metal into immediate contact with
the adjoining base metals and permitting the filler to penetrate the pores of the metal.

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 has 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.
 Fig. 5.3 brazing a butt joint

Difference between soldering and brazing

Soldering Brazing
1) Solder is used in this process. 1) Spelter is used in this process.

2) Joints are not very strong. 2) Joints are very strong.

3) Costs less 3) Costs more.

6) Suitable only for thin similar sheet 6) Suitable even for thicker similar or dissimilar metal
metals. parts
7) Soldered parts are to be cleaned with 7) Brazed parts are to be allowed to cool slowly.
water