Bachelor of Dramatic Art (Properties)

Subject: Properties Foundations Module: Metal Teacher: Marcelo Zavala-Baeza

Brazing
Brazing is a metal-joining process whereby a filler metal is heated above and distributed between two or more close-fitting parts by capillary action. The filler metal is brought slightly above its melting temperature while protected by a suitable atmosphere, usually a flux. It then flows over the base metal and is then cooled to join the work pieces together It is similar to soldering, except the temperatures used to melt the filler metal is above 450 C. There are different brazing processes or techniques that are used to join metals. Some of the most popular brazing processes include torch brazing, furnace brazing, silver brazing, vacuum brazing, dip brazing among others.
Flux In the case of brazing operations not contained within an inert or reducing atmosphere environment (i.e. a furnace), flux is required to prevent oxides from forming while the metal is heated. The flux also serves the purpose of cleaning any contamination left on the brazing surfaces. Flux can be applied in any number of forms including flux paste, liquid, powder or pre-made brazing pastes that combine flux with filler metal powder. Flux can also be applied using brazing rods with a coating of flux, or a flux core. In either case, the flux flows into the joint when applied to the heated joint and is displaced by the molten filler metal entering the joint. Excess flux should be removed when the cycle is completed because flux left in the joint can lead to corrosion, impede joint inspection, and prevent further surface finishing operations. Filler metals A variety of alloys are used as filler metals for brazing depending on the intended use or application method. In general, braze alloys are made up of 3 or more metals to form an alloy with the desired properties. The filler metal for a particular application is chosen based on its ability to wet the base metals, withstand the service conditions required, and melt at a lower temperature than the base metals or at a very specific temperature. Braze alloy is generally available as rod, ribbon, powder, paste, cream, wire and pre-forms (such as stamped washers). Depending on the application, the filler material can be pre-placed at the desired location or applied during the heating cycle. For manual brazing, wire and rod forms are generally used as they are the easiest to apply while heating. In the case of furnace brazing, alloy is usually placed beforehand since the process is usually highly automated. Some of the more common types of filler metals used are Aluminum-silicon Copper Copper-phosphorus Copper-zinc (brass) Gold-silver Nickel alloy Silver Amorphous brazing foil using nickel, iron, copper, silicon, boron, phosphorus, etc

Torch Brazing Torch brazing is considered to be the most versatile among all the brazing processes as its application can be found in almost any industry, be it the vast fabrication or repair work. Torch brazing is done in air. In torch brazing process, the necessary heat is provided by ordinary gas welding equipment by burning gas combinations such as air and acetylene, oxygen and acetylene, oxygen and hydrogen and air and propane. Torch brazing has some essential applications which as well hold importance in the brazing sector. They are commonly applied for small assemblies and low-volume applications. Torch brazing is generally used to join comparatively small assemblies which are made from materials that do not oxidize at the brazing temperature or can be protected from oxidation with brazing fluxes. The most commonly used filler metals while using torch brazing include aluminium-silicon alloys, silver-base alloys, and copper-zinc alloys. If a protective brazing atmosphere is not being used then flux is also needed with these filler metals. Self-fluxing copper-phosphorus alloys are also used.

Bachelor of Dramatic Art (Properties)

Subject: Properties Foundations Module: Metal Teacher: Marcelo Zavala-Baeza

Torch Brazing Equipment Oxygen cylinder with pressure regulator Fuel gas cylinder with pressure regulator Gas cylinders with trolleys for transportation Welding torch Red fuel gas hose Blue oxygen hose

Torch parts

Precautions to take when using Oxy-Acetylene torch -ALWAYS Wear safety glasses and insulating gauntlets at all times as well as welding jacket and boots. -ALWAYS Wear goggles with correct shade -REMOVE or confine loose clothing and tie hair back -ALWAYS Check all hoses & fittings for damage -Check O rings for wear cracks and MOST IMPORTANT! OIL, ANY OIL COMING INTO CONTACT WITH GASES CAN RESULT IN AN EXPLOSION!! -ALWAYS light the gas with a spark lighter WARNING!! Do not use any other ignition source as this can result in serious INJURY -Flame adjustment should always be done gradually to avoid flame snap out

Bachelor of Dramatic Art (Properties)

Subject: Properties Foundations Module: Metal Teacher: Marcelo Zavala-Baeza

Joining Process Brazing copper pipe may seem difficult, but it really does not have to be. Knowing when to braze and what flux material to use can make the job much simpler. Materials and equipment: Oxy acetylene torch flux pipe fittings wire brush rags small paint brush sandpaper Filler metals

Steps 1. Remove dirt and debris from the pipe and fittings. If you use a chemical cleaner make sure that is rinsed off well and that you do not touch the area to be brazed as oil from your hands can transfer and cause problems. 2. Use sandpaper to rough the surface to be brazed lightly. Also use the sandpaper to smooth the cut edge of your pipe. Clean the excess copper particles off the pipe. 3. Use the wire brush to rough up the inside of your fitting. Use a rag and pull through the fitting to clean any debris out of your tee or coupling. 4. Use paint brush to brush on the flux. Apply flux to the inside of the fitting, and around the end of your pipe. 5. Insert coupling on the end of your copper pipe. Brush on more flux where the two pieces meet to form a joint. 6. Start the acetylene torch and allow it to run for a few seconds. You want a reduced flame when brazing pipe. You want to heat the surface to be brazed quickly and evenly to ensure a good bond. 7. Lightly move flame over the fitting where the flux has been applied. Evenly applying heat to the entire surface. Constantly move the flame to be sure that there is no burn through spots on the pipe or fitting. 8. Only apply enough heat to get the filler material/solder to flow freely. Holding the solder to the hot pipe will cause the solder to melt and join the pipes together. Make sure the solder goes 360 degrees around the pipe and flows into the small space between the inside of the fitting and the outside of the pipe. 9. After the pipe has naturally cooled clean any excess flux off with warm water. Any flux residue left behind can be removes with a wire brush.

Bachelor of Dramatic Art (Properties)

Subject: Properties Foundations Module: Metal Teacher: Marcelo Zavala-Baeza

Flame types

Reducing (Carburising) uses more fuel than oxygen/air good for annealing deep blue colour three heat zones

Neutral uses equal amounts of oxygen/air and gas good for soldering, brasing and fast annealing two colour of flame (medium blue colour) two heat zones

Oxidising uses more oxygen/air than fuel (unburnt oxy/air forced into material and use up flux) Use for welding pale lavender colour hissing sound (can make heating difficult to control)