Induction brazing and soldering

Brazing and soldering is a method of joining metals by applying a filler metal of low melting temperature between the metals to be joined. When the filler metal melts it slightly diffuses into the base metals thus holding the parts together.

Soldering is divided into two classifications: soft and hard. In soft soldering filler metals with low melting temperature are used, while in hard soldering the melting temperature of filler metals is comparatively high.

In recent years, many complex forgings and stampings have been re-designed to allow fabrication by brazing or soldering of parts produced by mass-production techniques¹. Such new designs have often resulted in striking reductions in cost². In other instances, brazing and soldering have permitted the construction of assemblies too costly or complex to be produced by other techniques. Induction heating has proved to have been a valuable aid in these joining processes for many reasons. Among these are rapid heating and precise heat control. The former offers the possibility of localized heating for joining high-strength components with minimum loss of strength. The latter permits sequential brazing or soldering operations to have been performed effectively. Rapid heating also minimizes discolouration and thus facilitates cleaning.

Uniform joints with smooth fillets, obtained by induction soldering and brazing, decrease alloy consumption and produce parts which are identical in appearance³. Frequently, induction brazing and soldering permit a reduction in the required number of holding fixtures. At the same time, the resultant minimum of the fixtures increases their life and maintains their accuracy in alignment of the components to be joined. Basically, brazing and soldering involve fusion of a joining alloy between the surfaces of metal parts to be joined. If the metal surfaces are clean, intimate contact⁴ is established and the joining material alloys with each surface, forming a joint upon solidification during cooling. The two methods of joining differ primarily in the type and melting temperature of the alloy used to form the joint. In soldering, low-melting-temperature alloys, generally containing lead and tin, permit joints of limited strength to be made at temperatures below 800°F. Soldering with these alloys is often termed "soft soldering" and is used in fabricating radio condenser cans⁵, radiators, terminal strips, instrument cases, etc., and with the metals to be joined consisting of copper and copper alloys such as brass and bronze, carbon and alloy steels, nickel alloys and clad or plated aluminium. Thorough cleaning prior to and during heating is basic for successful soldered joints.

Many joint failures may have been traced directly to poor cleaning and inadequate fluxing. Surfaces to be joined should have been chemically cleaned (freed of heat treatment scale, corrosion products, grease, embedded graphite, etc.) prior to heating, and the joint areas fluxed as soon as possible to avoid contamination from handling or exposure. Suitable fluxes prevent oxidation of the joining alloy and metal surfaces to be joined and also dissolve any residual oxides during heating. They improve the wetting characteristics⁶ of the joining alloy, thus promoting its free flow upon melting. Zinc chloride and ammonium chloride fluxes in paste form are most frequently used in induction soldering, since they are the most active. Unfortunately, these fluxes leave residues which are corrosive, electrically

conductive and hygroscopic. Such flux residues must be thoroughly removed. When this is impossible, as in soldering fine electrical assembly units, rosin or activated rosin-type fluxes which leave non-corrosive and electrically non-conductive residues are used. Fluxes for induction soldering are usually used in paste or liquid form.

¹. mass-production techniques - технические методы серийного производства

². to result in striking reductions in cost - вызывать резкое снижение стоимости

³. identical in appearance - одинаковые по внешнему виду

⁴. intimate contact — прочный контакт

⁵. radio condenser can - корпус радиоконденсатора

⁶. wetting characteristics - характеристики смачивания

Дата добавления: 2014-12-27