soldering and brazing of aluminium
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SOLDERING AND BRAZING OF ALUMINIUM
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contents What are soldering and brazing Soldering of Aluminium Brazing of Aluminium Aluminium soldered \ brazed products Solerabilty of aluminium alloys Brazeabilty of aluminium alloys Solders Filler metal used in brazing Aluminium Fluxes Soldering methods Brazing methods Soldering \ brazing Aluminium to other metals Is soldering or brazing more suitable
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What are soldering and brazing ?
Joining process using a heating method and a filler metal without melting the base materials .
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SOLDERING BRAZING
Filler metal has a liquidus below 800 F .
Joint strength ↓ cost ↓ resistance to corrosion ↓.
Filler metal has a liquidus above 800 F .
Join strength ↑ cost ↑ resistance to corrosion ↑
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Advantages of soldering and brazing
Joining dissimilar metals and non-metals allows much tighter control over
tolerances Low temperature compared to welding less thermal distortion clean joint Speed of joining Easy realignment Less manual skills
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Disadvantages
the lack of joint strength .
joint colour
damaged under high temperature condition .
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Soldering of Aluminium
Active fluxes Low temperature soldering
390 F → 650 F
High temperature soldering
250 F → 400 F below Al-alloys melting point
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Brazing of Aluminium Close temperature control is required . The brazing temperature should preferably be
70 F below melting point of Al
In condition of accurately controlled of temperature
it can be done at 10 F
Most brazing is done between
1020 →1180 F
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• Aluminium products joined by brazing/soldering
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• Aluminium frames
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Solderability of Aluminium alloys
Almost all aluminium alloys can be soldered
Alloys containing more than 1% Mg can not be soldered satisfactorily . (5xxx _ 6xxx)
(intergranular penetration )
Alloys containing more than (5%) Si can not be soldered (4xxx \ 6xxx)
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Brazeability of Aluminium alloys
1xxx , 3xxx , 6xxx and low-Mg members of 5xxx are most successfully brazed alloys
2xxx , 7xxx not normally brazed because of low melting temperature .
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Solders
1.Low-temperature
Melting between 300 F → 500 F Composed of Tin, lead, zinc, cadmium And small amount of Al ,copper ,Nickel Good low-temperature solder used in
aluminium soldering is : The eutectic alloy containing : 91%SN , 9%ZN Melts at 400 F
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Solders
2. Intermediate-temperature solder
Melts at 500 F → 700 F
Contains : Tin ,Zinc < 30% → 70%> and Small amount of copper, lead and silver
Stronger joints
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Solders 3.High-temperature solders :
Melts between 700 → 800 F .
Containing from 90% → 100% Zn and from
2% → 10% Al .
Strongest and superior corrosion resistance .
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Filler metals for brazing Aluminium
Powder , paste or wire
Commercial filler metal alloy using in Al-brazing are :
Aluminium-silicon alloys containing 7%→12 Si
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To reduce brazing temperature the following alloy elements were added :
1. copper → intermetallic compound AL-Cu 2. Germanium → expensive 3. Beryllium → healthy hazards
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Flux Flux function
Aluminium brazing fluxes contain chlorides and fluorides
Aluminium soldering fluxes1.Organic : melts 400 → 525 F Contain zinc fluoride or zinc chloride 2. Non-organic : melts 540 → 720 F
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Soldering methods Iron soldering Common in Al assemblies Furnace soldering Large assemblies Abrasion soldering no flux
Induction soldering rapid
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Flame soldering manual or automatic , No limitation on thickness
Dip soldering High production rate
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Brazing methods Torch brazing economical
Furnace brazing ↑ production rate
Dip brazing the best method for AL
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Soldering other material to Aluminium
Any solderable material can be soldered to Aluminium .
Magnesium, titanium, tungsten , are difficult to solder to Aluminium .
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Brazing Al to other metals
Al can be brazed to many other metals
Al to copper : is difficult to braze because of low melting temperature (1018 F) of Al-copper eutectic composition .
Al to steel : possible (dip brazing) Al to magnesium : easy but brittle
joint .
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Is soldering or brazing more suitable?
That depends on :
1. Strength requirements brazed joints can be 3 – 10 the strength of soldered joints
2. Corrosion resistance solders are less corrosion resistance
3. Temperature
4. Cost
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Thank you