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2011
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09
Common process methods for soldering materials
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The main process parameters of brazing are brazing temperature and holding time. The brazing temperature is usually selected to be 25 to 60 °C above the liquidus temperature of the filler metal to ensure that the filler can fill the gaps.
The holding time for brazing depends on the size of the workpiece and the intensity of interaction between the filler metal and the base material. Larger workpieces require a longer holding time to ensure uniform heating. If the interaction between the filler metal and the base material is strong, the holding time should be shorter. Generally speaking, a certain holding time is necessary to promote diffusion between the filler metal and the base material, forming a strong bond. However, excessive holding time can lead to defects such as erosion.
There are many commonly used brazing methods, mainly classified according to the equipment used and working principles. For example, based on heat sources, there are infrared, electron beam, laser, plasma, and glow discharge brazing; based on working processes, there are contact reaction brazing and diffusion brazing. Contact reaction brazing utilizes the reaction between the filler metal and base material to generate a liquid phase that fills the joint gap. Diffusion brazing increases the holding diffusion time to fully homogenize the weld seam with the base material, thereby obtaining joints with properties similar to those of the base material. Almost all heating sources can be used as brazing heat sources, thus classifying brazing.
Soldering iron brazing is used for soft soldering of small or very thin parts.
Wave soldering is used for assembling and welding large quantities of printed circuit boards and electronic components. During soldering, molten solder at around 250 °C forms waves through a narrow gap under pump pressure, allowing workpieces to be welded as they pass through the wave. This method has high productivity and can achieve automated production on assembly lines.
Flame brazing uses a flame generated by burning a mixture of combustible gas and oxygen or compressed air as a heat source for welding. Flame brazing equipment is simple and easy to operate; multiple flames can be used simultaneously for heating and welding depending on the shape of the workpiece. This method is suitable for welding medium and small parts such as bicycle frames and aluminum kettle spouts.
Dip brazing involves partially or fully immersing workpieces in a bath of filler metal covered with flux or in a salt bath containing only molten salt for heating and welding. This method provides uniform and rapid heating with relatively accurate temperature control, making it suitable for mass production and welding large components. The salt in the salt bath is mostly composed of flux. After welding, workpieces often retain a large amount of flux, resulting in significant cleaning workload.
Induction brazing uses high-frequency, medium-frequency, or industrial-frequency induced current as a heat source for welding. High-frequency heating is suitable for welding thin-walled pipe fittings. Coaxial cables and split-type induction coils can be used for brazing at sites away from power sources, particularly suitable for certain large components such as pipe joints that need to be disassembled on rockets.
Furnace brazing involves placing workpieces assembled with filler metal in a furnace for heating and welding; flux may often be added, and reducing gases or inert gases can also be used for protection, providing relatively uniform heating. Continuous furnaces can be used for mass production.
Vacuum brazing involves heating workpieces in a vacuum chamber, mainly used for welding products that require high quality and materials that are prone to oxidation.
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