& Mechanical Fastening process Brazing Joining process
A filler metal is placed between two workpieces and heated until melted
Two main types of Brazing Ordinary Braze welding
Use of flux is very important Filler Metals Available in a wide range of brazing temperatures
They come in a wide range of shapes
Choice of the filler metal and its composition are important
Diffusion of the filler metal in to the workpeice is an important consideration Fig: a) Brazing b) Braze welding operation Fluxes The use of flux in brazing is very important
Generally made of: Borax Boric acid Borates Fluorides Chlorides
Wetting agents may also be added Brazing Methods Torch Brazing
Performed by heating the joint with a torch
Depositing the filler metal in the joint
Suitable part thickness (0.25 6.0)mm
Not a automated process
More than one torch can be used in this process Furnace Brazing Precleaned & Preloaded with brazing metal Heated in a furnace Fig:An example of furnace brazing a)before b) after Brazing Methods Other Types Of Brazing Induction Brazing
Resistance Brazing
Dip Brazing
Infrared Brazing
Diffusion Brazing Braze Welding Prepared like fusion welding
Filler metal is deposited at the joint with the use of an oxyacetylene torch
Considerably more filler is used
Temperature is minimal compared to that of fusion welding; part distortion is minimal Brazing Process Capabilities Dissimilar metals can be assembled with good joint strength
Shear strength of brazed joints can reach 800Mpa Fig:Joint Designs commonly used in brazing operations.The clearance between the two parts being brazed is an important factor in joint strength.If the clearance is to small, the molten braze metal will not fully penetrate the interface. Good/Poor Designs Soldering Different types of soldering
Torch Furnace Iron Induction Resistance Dip Infrared Ultrasonic reflow (paste) Wave Reflow Soldering Solvents present in the paste are evaporated
The Flux in the paste is activated and the fluxing action occurs
The components are carefully preheated
The solder particles are melted and wet the joint
The assembly is cooled Wave Soldering Popular approach to attaching circuits to circuit boards Fig: a)Screening or stenciling paste onto a printed circuit board: 1) Stenciling process 2) a section of a typical stencil pattern b) wave soldering process Types Of Fluxes Inorganic acids or salts clean the surface rapidly
Noncorrosive resin- based used in electrical applications
Soldering is used extensively in electronics industry Adhesive Bonding
Products are joined and assembled by the use of Adhesives
Adhesives properties to be considered Strength Toughness Resistance to various fluids Ability to wet the surface to be bonded Types of adhesives Surface must be clean for joining parts
Should avoid joints that might be subjected to peeling forces Design for adhesive bonding Adhesive Peeling Test Fig : Characteristic behavior of (a) brittle (b) tough adhesive in a peeling test Joint Design in Adhesive Bonding Fig:Various joint design in adhesive bonding. Configurations for adhesive bonds Fig : (a) single lap (b) double lap (c) scarf (d) strap Mechanical Fastening Threaded Fasters Bolts Screws Nuts
Other Fastening Methods Stapling Crimping Snap-in Fasteners Shrink and press fits Rivets Fig:a)solid b)tubular c) split (bifurcated) d) compression Fig : Design guidelines for riveting (a)Exposed shank is too long; the result is buckling instead of upsetting (b)Rivets should be placed sufficiently far from edges to avoid stress concentrations (c)Joined sections should allow ample clearance for riveting tools (d) section curvature should not interfere with the riveting process Joining Plastics Heat softens the plastic to a molten state
Then pressure added & fusion takes place
External Heat Sources Hot air Heated tools & dies Electrical-Resistance Lasers
Internal Heat Sources Ultrasonic welding Friction welding THE END