En P 01 PrinciplesOfBrazingTechnology

Principles of brazing technology
Brazing is a thermal process for securely joining and coating materials, whereby a liquid phase is produced by melting a brazing alloy (fusion-brazing) or by diffusion at the interfaces (diffusion-brazing). The solidus temperature of the base material is not reached (DIN 8505, Part 1). 1. Standards and regulations for brazing 1.1 Recommendations for brazing - Technical information sheets - Standards Technical information sheets: Recommended These are prepared by experts in work groups and the information corresponds to the respective state of technology. It is recommended that the technical information sheets be heeded as they are also viewed as the respective state of the technology from a legal point of view. Examples: DVS-Guideline 1183: DVS-course Brazing copper materials VdTV Technical Information Sheet 1160: Evaluation of processes for manufacturing brazed joints and high temperature brazed joints DVGW Work Sheet GW2
Virtually identical melting temperatures for the base material and alloy
1.2 Regulations for work safety and accident prevention, e.g.: - Accident prevention regulations, section 15: Welding and related techniques d.BG; - VDI 2046 Safety guidelines for operating industrial furnaces with inert gas and reactive atmospheres 2. Wetting process and capillary forces 2.1 Distinction between welding and brazing In welding not only is the added alloy material melted but the base material is also partially melted. In brazing only the added brazing alloy melts. The base material is wetted in its solid state by the liquid brazing alloy.
Fusion welding Brazing
Usually similar materials
Virtually any desired material combinations

Brazing alloy melts at lower temperature than the base material
Standards: Compulsory Any deviation from the standard must be specifically agreed between the client and contractor. There are currently many national (DIN), european (EN) and international (ISO) standards. The existing German standards are being superseded by European standards. Referral is made in particular here to DIN EN 1044 Brazing composition of brazing alloys which replaces DIN 8513 Parts 1-5 and to DIN EN 1045 Brazing fluxes for brazing which replaces DIN 8511-1. Both these standards categorise the respective materials. There are also standards in existence which cover the terms used in brazing, constructional aspects, testing of brazed joints, inspecting brazed joints, etc. which can be obtained via Beuth-Verlag (Berlin) or DVS-Verlag (Dsseldorf).
2.2 Wetting A prerequisite for brazing is the wetting of the base material by the brazing alloy. Three important conditions must be fulfilled for this to happen: the brazing surfaces and the brazing alloy must be bare metal, the brazing surfaces and the brazing alloy must have at least reached the working temperature, at least one component of the brazing alloy must readily form an alloy with the base material.
Umicore AG & Co. KG - BrazeTec, Rodenbacher Chaussee 4, D-63457 Hanau-Wolfgang Telefon: +49 (0) 6181-59-03 Telefax: +49 (0) 6181-59-3107 Email: info@BrazeTec.de Internet: www.BrazeTec.de
Base material
1 to 1.5 mm
Visible oxide layers (rust and scale), fat layers and layers of dirt must be removed before carrying out brazing work. Thin oxide layers (e.g. tarnishing) may remain on the workpieces if brazing is carried out using a flux. The working temperature is the lowest surface temperature of a workpiece at the brazing joint at which the brazing alloy can wet, spread and bond with the base material. This temperature is always higher than the solidus temperature of the brazing alloy. It can be above, below or the same as its liquidus temperature.
The most important area of application of jointbrazing is for brazing galvanised steel pipes.
The wetting process involves surface alloying between the brazing alloy and the base material. Next to the wetting zone there is a diffusion zone which is very small for brazing work and cannot be detected by metallographic means. In order to attain optimum strength, the brazing alloy must be liquid for at least 8 to 10 seconds to give an adequately deep diffusion zone.
There is greater interaction between the brazing alloy and base material when carrying out high temperature brazing (flux-free brazing at temperatures above 900C in a controlled atmosphere). 2.3 Joint-brazing and gap-brazing Joint-brazing is a brazing technique similar to gasfusion welding from a joint preparation and working method point of view. It is virtually always carried out manually. The working temperature of the brazing alloy must not be exceeded when joint-brazing.
The workpieces are prepared for gap-brazing such that the brazing joints are narrow capillary gaps. They are heated up to brazing temperature uniformly over the whole length of the gap. The liquid brazing alloy is forced into the gap by capillary filling pressure. This technique is easy to mechanise. The majority of brazing work is carried out by the gapbrazing technique. The surface forces are additive in the narrow capillary gaps (size of the order of 0.1 mm), so that the brazing alloy is preferentially drawn into the narrow gap. If brazing is being carried out with a flux in a gas atmosphere, the brazing alloy which penetrates into the brazing gap must be able to push the flux out of the gap. In gap-brazing, the working temperature of the brazing alloy may be exceeded by in general 20 to 50C.

Start of the wetting Intermediate state
Gap too narrow (only applies for brazing with flux)
Correct gap width
II = Workpiece 1 II = Workpiece 2 Both bare metal, and heated to working temperature Liquid brazing alloy
Final state
Permissible gap width for manual brazing Gap too wide
Capillary filling pressure The brazing alloy is pressed into the gap by capillary forces. The narrower the brazing gap, the higher the capillary filling pressure.
Different gap cross-sections give different filling pressures. An open fillet has a six times higher capillary filling pressure than a parallel flat gap.
3. Brazing alloy and flux groups 3.1 Brazing alloys According to DIN 8505, alloys with a liquidus temperature below 450C are solders and those with a liquidus temperature above 450C are brazing alloys. The upper and lower brazing temperature limits are determined by the following: lower limit - the working temperature For a 0.1 mm parallel gap, the capillary filling pressure reaches ca. 100 mbar, corresponding to about 0.1 Atm. This in turn corresponds to about a 1 m column of water ( = 1); assuming = 10 g/cm3 (the density of a brazing alloy), the capillary height for low melting point brazing alloys in a 0.1 mm wide gap can be calculated to be ca. 10 cm. This agrees reasonably well with experiences in practice. upper limit the flux (becomes saturated with oxides at too high temperatures), or the brazing alloy (individual components of the alloy can evaporate), or the economics of the process (unnecessarily high temperatures cost unnecessary time and energy), or the base material (structural transformation; strength loss).

3.2 Fluxes Fluxes are solvents for metal oxides. They have an effective temperature range within which they are able to dissolve metal oxides. The solvating capacity of the flux is limited. About 5% of the weight of flux in metal oxides can be dissolved. If oxides are present in greater amounts, the flux saturates and it loses its functionality.
Atmospheric oxygene Flux Oxide
naturally has a big effect on the soundness of the brazed joint.

Flux
Wire of brazing alloy
More than 5 min.
The hygroscopic flux residues must be removed by scouring in water or by pickling in pickling baths suitable for the base materials. Ultrasound aids the removal of these flux residues. The non-hygroscopic flux residues do not have to be removed for fear of corrosion. If they need to be removed for other reasons (e.g. to paint the components), they are usually removed by mechanical means (e.g. sand-blasting).
Too little Sufficient
For surface brazing, the high capillary filling pressure in the open fillets leads to running of the brazing alloy on the external sides. The supply of brazing alloy to the narrow surface gap is reduced; increased inclusion of flux hence occurs.
Brazing alloy Flux
Increased flux inclusion can be avoided by inserted brazing alloy sheet.

Oxide film remains Oxide film is dissolved
Gaseous fluxes Joints (V-seams and fillets) can be brazed using gaseous fluxes. For brazing gaps especially for gaps having larger depths and small widths the use of gaseous fluxes is not recommended because the flame does not penetrate into the capillary gap. When using flux pastes, their working life can be significantly prolonged by the additional use of gaseous fluxes. The effective temperature of gaseous fluxes extends from about 750C to 1100C.
The solvating capacity of modern brazing fluxes for use at low temperatures (i.e. between 600 and 800C) for common heavy metal oxides is between 1 and 5%, meaning that it is limited. That means that relative to the oxide which is present a relatively large amount of flux must be available, and ultimately so in the molten state, otherwise sound brazing work is not achieved. Extremely narrow gaps, e.g. less than 0.02 mm, hence cause problems because there is an inadequate amount of flux in the gap. This

Brazing with flux-forming brazing rods - BrazeTec Silfos brazing alloys. 4. Brazability of components According to DIN 8514, the brazability is the property of a component to be manufactured in such a way via brazing that it meets the stipulated requirements. A component can be brazed if the following conditions are met (see diagram): the base material is suitable for brazing, there is a brazing capability for the manufacture, namely one or more brazing techniques can be used, and the construction can be brazed such that a sound construction results, namely satisfactory reliability of the component under the foreseen operating conditions.
Oxygen Fuel gas
Comment: In electrical engineering, the expressions solderability and suitability for soldering are used synonymously for soldering. Base material Copper alloys, copper-tin alloys and silver can be brazed with phosphorus-containing brazing alloys without the use of flux. The self-flowing properties of these brazing alloys can be explained as follows: On melting the brazing alloy, the phosphorus in the brazing alloy reacts with oxygen in the air to form phosphorus pentoxide. This reacts with the copper protoxide on the copper surface to form copper metaphosphate which acts as a flux. As copper metaphosphate is safe from a chemical- corrosion point of view, the brazed joints require no subsequent treatment. When brazing with BrazeTec Silfos brazing alloys, the brazing time should not be longer than about 3 to 4 minutes. Suitability for brazing
Brazability of the component Brazing capability Manufacture
Soundness of the brazed joint Construction
Suitable base material, brazing alloy and flux combinations Each of the three properties suitability for brazing, brazing capability and ability to manufacture a sound brazed joint depend on the base material, manufacturing process and joint design. The degree of dependency on these three parameters depends on the individual brazing task.

The suitability of base materials for brazing work is shown in Table 1. Tables 1 and 3 give information about how the indicated materials can be brazed. This does not mean to say that components brazed in this way can withstand all operating loads. In order to guarantee this, the operating conditions for the brazed joints must be known prior to selecting the conditions/methods for carrying out the brazing work. These are workpiece-specific and differ from one component to the next. More detailed information on this matter can be found in the section entitled Selection criteria for brazing alloys and fluxes. In certain instances where there is relatively high risk of damage, we recommend that you get in touch with us to enable optimum selection of the brazing parameters. Brazing has the big advantage that virtually all materials which are suitable for brazing can be combined with each other. It goes without saying that the brazing parameters must always be selected for the most difficult material from a brazing point of view.
Suitability of base materials for brazing Group 1 Materials which can be brazed with universal brazing alloys and universal fluxes and using all standard techniques. e.g. copper and copper alloys nickel and nickel alloys iron materials common steels cobalt noble metals Table 1 Group 2 Group 3
Materials which require special Materials which can only be brazing alloys and/or special fluxes, brazed using special brazing but which do not require special alloys and special techniques. brazing techniques. e.g. aluminium and aluminium alloys hard metals, stellites chromium, molybdenum, tungsten, tantalum, niobium solder-like materials e.g. titanium zirconium beryllium ceramics

Solder and brazing alloy groups (I) Group description Soldering / brazing temperature range C 145 ... 325 145 ... 395 Typical solders / brazing alloys in this group in accordance with EN (DIN) S-Sn60Pb40 S-Pb50Sn50 S-Sn97Cu 3 S-Sn96Ag4 S-Sn96Ag3 S-Sn95Sb5 AG 104 (L-Ag45Sn) AG 106 (L-Ag34Sn) AG 203 (L-Ag44) AG 207 (L-Ag12) CU 303 (L-CuZn40) CU 102 (L-Cu) Low melting point 610 ... 800 cadmiumcontaining universal brazing alloys DIN EN 1044 (DIN 8513) Manganese690 ... 1020 containing special brazing alloys DIN EN 1044 (DIN 8513) 1) not laid down in standards Table 2a AG 304 (L-Ag40Cd) AG 306 (L-Ag30Cd) BrazeTec 4003 BrazeTec 3003 BrazeTec name Solidus temp. C 183 183 230 221 Liquidus temp. C 190 215 250 221 240 680 730 735 830 895 1083 630 690 150 150 Max. permissible Most important continuous areas of application operating temperature 1) C 80 Electro-industry 80 110 Copper pipe installation for hot and cold water systems 110 Food industry 110 200 200 300 300 350 Refrigeration engineering Gas and water installation Gas and water installation Electrical engineering Galvanised steel pipes, steel furniture Inert gas brazing of massproduced components Electrical engineering Refrigeration engineering Car-suppliers-industry
Tin-lead solders EN 29453 Special solders EN 29453
Soldamoll 230 (BrazeTec 3) Soldamoll 220 BrazeTec 4 Soldamoll 235 BrazeTec 4576 BrazeTec 3476 BrazeTec 4404 BrazeTec 1204 BrazeTec 60/40
Cadmium-free universal brazing alloys DIN EN 1044 (DIN 8513)
650 ... 1100
640 630 675 800 875 1083 595 600
AG 502 (L-Ag49)
BrazeTec 4900 BrazeTec 21/68
680 980
705 1030
400 600
Hard metal tools Hard metal tools
Solder and brazing alloy groups (II) Group description Soldering / brazing temperature range C 710 ... 800 Typical solders / brazing alloys in this group in accordance with EN (DIN) CP 102 (L-Ag15P) CP 105 (L-Ag2P) CP 203 (L-CuP6) 730 ... 960 AG 403 (L-Ag56InNi) BrazeTec name Solidus temp. C BrazeTec Silfos 15 BrazeTec Silfos 2 BrazeTec Silfos 94 BrazeTec 5603 BrazeTec 6009 BrazeTec 7200 BrazeTec 897 BrazeTec 1135 BrazeTec 1002 BrazeTec 88/12 645 645 710 600 600 780 890 1080 970 575 Liquidus temp. C 800 825 890 710 720 780 890 1135 1000 590 200 Max. permissible continuous operating temperature 2) C 150 150 150 200 200 300 Most important areas of application
Phosphoruscontaining brazing alloys for copper base materials DIN EN 1044 (DIN 8513) Special brazing alloys for special brazing work DIN EN 1044 (DIN 8513) High temperature nickel-based brazing alloys DIN EN 1044 (DIN 8513) Aluminium brazing alloys DIN EN 1044 (DIN 8513) Table 2b
Electro-industry Copper pipe installation for sewer gas / natural gas High grade steel High grade steel Vacuum technology Core and reactor constr. Turbine construction Turbine construction Heat exchangers
900 ... 1200
Ni 107 (L-Ni7) Ni 105 (L-Ni5) Ni 102 (L-Ni2) AL 104 (L-AlSi12)
560 ... 600

Flux groups (I) for soldering/brazing metallic materials Flux group Flux type 3.2.2. 3.1.1. 3.1.1. 2.1.3 Fluxes for soldering heavy metals DIN EN 29454 2.1.1 2.1.2. 1.1.2. 1.1.1. 1.1.3. Fluxes for soldering light metals DIN EN 29454 3.1.1. Information about the manufacture Most important areas of application Zinc chloride and/or ammonium Chromium-containing steels; chloride and free acids highly oxidised workpieces Zinc chloride and/or ammonium chloride Zinc chloride and ammonium chloride in organic formulation Organic acids Amines, diamines, urea Organic halogen compounds Resins with halogen-containing activators Resins without additives Resins with halogen-free additives Solder-forming zinc chlorides and/or tin chlorides; also with additives Organic compounds Organic halogen compounds For workpieces which can be washed Corrosive Copper Non-corrosive Chromium-free steels and non-noble metals, if washing off the flux residues is not possible Partly corrosive Chromium-free steels and non-noble metals, if washing off the residues is possible Nature of flux residues Corrosive
2.1.3. 2.1.2.
Table 3a

Flux groups (II) Flux group Flux type Information about the manufacture Boron compounds and fluorides Most important areas of application Behaviour of the flux residues
Fluxes for brazing FH10 heavy metals FH11 DIN EN 1045 FH12 FH20 FH21 FH30 FH 40
Silver brazing alloys with working temperatures up to Hygroscopic ca. 800C Brazing alloys with working temperatures between 750 and ca. 1000C Brazing alloys with working temperatures above 1000C Non-hygroscopic Non-hygroscopic
Boron compounds Boron compounds, phosphates, silicates Chlorides and fluorides
Hygroscopic Brazing alloys with working temperatures between 600 and 1000C for reactor construction (boron-free) For workpieces which can be washed (also pickled, neutralised) Heat exchangers Corrosive Non-corrosive
Fluxes for brazing FL10 light metals DIN EN 1045 FL20 Table 3b
Hygroscopic chlorides and fluorides Non-hygroscopic fluorides

Proposals (I) for brazing alloy (solder) / flux / brazing (soldering) technique combinations (for Group 1 base materials in accordance with Table 3) Base material Cu Cu-alloys Ni + Ni-alloys Iron materials Common steels Cobalt Cr- and Cr/Ni-steels Brazing alloy CP 105 (L-Ag2P) CP 203(L-CuP6) CP 105 (L-Ag2P) AG 102 (L-Ag55Sn) AG 203 (L-Ag44) AG 102 (L-Ag55Sn) AG 203 (L-Ag44) AG 304 (L-Ag40Cd) CU 303 (L-CuZn40) CU 305 (L-CuNi10Zn42) CU 102 (L-Cu) AG 403 (L-Ag56InNi) NI107/NI105/NI102 AG 401/CU102 AG 102 (L-Ag55Sn) AG 202 (L-Ag60) AG 401 (L-Ag72) Gold brazing alloys Flux FH10 FH10 FH20 FH12 FH10 FL / Ind. / EL.-W. SO / VO FL / Ind. EL.-W. AO SO / VO S-Sn96Ag4 3.1.1. Technique *) FL / Ind. EL.-W / SO / VO Solder S-Sn97Cu3 S-SnAg4 S-Pb50Sn50 S-Pb50Sn50 S-Sn96Ag4 S-Sn97Cu3 S-Cd82Zn16Ag2 S-Sn96Ag4 Flux 3.1.1. 1.1.1. Technique *) FL / EL.-W.
FL / Ind / EL.-W. / AO SO / VO
3.1.1. 3.1.1. 3.2.2.
FL / EL.- W. / Ind. HL / AO / FL / Ind. FL / EL.-W./ K HL / AO
Noble metals
*) FL = Flame; EL.-W. = Electr. Res.; SO = Inert gas furnace; K = Copper-bit; Ind. = Induction; AO = Atmosphere furnace; VO = Vacuum furnace; HL = Hot air jet Table 4a

Proposals (II) for brazing alloy (solder) / flux / brazing (soldering) technique combinations (for Group 2 and 3 base materials in accordance with Table 3) Base material Al and Al-alloys (with Mg and/or Si contents 2%) Hard metals Stellites Brazing alloy AL 104 (L-AlSi12) AG 301 (L-Ag50CdNi) AG 502 (L-Ag49), possibly as layer brazing alloy AG 502 (L-Ag49) CU 305 (L-CuNi10Zn42) CU 102 (L-Cu), possibly with tri-metal AG 502 (L-Ag49) Cu87MnCo 1) AG 401 (L-Ag72) PD 105 PD 105 Flux FL10 FH12 FH12 FH21 FH12 FH21 Technique *) FL AO FL Ind. SO / VO Solder S-Sn96Ag4 S-Cd80Zn20 Flux 3.1.1. Technique *) FL / (K) -
Chromium, molybdenum, Tungsten, tantalum, niobium Zinc Antimony Lead Bismuth Tin Titanium
FL/Ind. AO/SO -
S-Pb60Sn40 S-Sn96Ag4 S-Sn50Pb32Cd18
3.1.1. 3.1.1. -
FL/EL.-W. K/HL FL/EL..-W. K/HL -
Zirconium Beryllium Graphite AgCuTik 1) Metal oxideceramics *) FL = Flame; EL.-W. = Electr. Res.; SO = Inert gas furnace; K = Copper-bit; Ind. = Induction; AO = Atmosphere furnace; VO = Vacuum furnace; 1 HL = Hot air jet ) not laid down in standards Table 4b
SO (Argon) VO SO (Argon) VO SO (Argon) VO

The information given about our products, equipment, plants and processes is based on extensive research work and our technical knowledge of applications. We provide this information verbally and in writing according to the best of our knowledge, but we do not accept any responsibility beyond that in the individual contract. We do however reserve the right to make technical changes as part of our product development activities. Our technical service personnel are available on request to provide further advice and assistance to solve manufacturing and technical problems. This does however not relinquish users of their responsibility to check our information and recommendations prior to carrying out their own work. This is also true especially for deliveries abroad with regard to the observance of protection rights of third parties and with regard to applications and procedures not expressly given in writing by us. In the event of damage, our liability is limited to compensation to the same degree as provided for in our General Terms and Conditions of Sale and Delivery for shortcomings in quality.
BrazeTec GmbH, Rodenbacher Chaussee 4, D-63457 Hanau-Wolfgang Telefon: +49 (0) 6181-59-03 Telefax: +49 (0) 6181-59-55 50 Email: info@BrazeTec.de Internet: www.BrazeTec.de

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En P 01 PrinciplesOfBrazingTechnology

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Principles of brazing technology

Usually similar materials

Virtually any desired material combinations

Principles of brazing technology

Principles of brazing technology

Correct gap width

Permissible gap width for manual brazing Gap too wide

Principles of brazing technology

naturally has a big effect on the soundness of the brazed joint.

Wire of brazing alloy

More than 5 min.

Brazing alloy Flux

Increased flux inclusion can be avoided by inserted brazing alloy sheet.

Principles of brazing technology

Oxygen Fuel gas

Brazability of the component Brazing capability Manufacture

Soundness of the brazed joint Construction

Principles of brazing technology

Principles of brazing technology

Tin-lead solders EN 29453 Special solders EN 29453

Cadmium-free universal brazing alloys DIN EN 1044 (DIN 8513)

650 ... 1100

640 630 675 800 875 1083 595 600

BrazeTec 4900 BrazeTec 21/68

Hard metal tools Hard metal tools

Principles of brazing technology

900 ... 1200

Ni 107 (L-Ni7) Ni 105 (L-Ni5) Ni 102 (L-Ni2) AL 104 (L-AlSi12)

560 ... 600

Principles of brazing technology

Principles of brazing technology

Boron compounds Boron compounds, phosphates, silicates Chlorides and fluorides

Hygroscopic chlorides and fluorides Non-hygroscopic fluorides

Principles of brazing technology

3.1.1. 3.1.1. 3.2.2.

FL / EL.- W. / Ind. HL / AO / FL / Ind. FL / EL.-W./ K HL / AO

Principles of brazing technology

S-Pb60Sn40 S-Sn96Ag4 S-Sn50Pb32Cd18

FL/EL.-W. K/HL FL/EL..-W. K/HL -

SO (Argon) VO SO (Argon) VO SO (Argon) VO

Principles of brazing technology

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