In the age of discrete manufacturing and Industry 4.0, OEMs are working hard to shorten the time a piece of equipment spends on the production line while still retaining the high quality of the product. Brazing is one of the procedures OEMs use to fulfil their demand for speed and accuracy. Brazing is a technique that uses a filler material, known as a brazing alloy, to join two or more dis-similar metal parts.
The Brazing Process
Brazing, which is considered an extremely specialised and artistic manner of joining two metals components, usually is a 5-step process:
Step 1: Surface Preparation
The surfaces to be brazed are properly cleaned to remove any dirt, oxides, or impurities. This ensures the brazing alloy and base metals are properly wetted and bonded.
Step 2: Flux Application
Before brazing, a chemical compound known as a flux is applied to the joint region to avoid oxide formation, promote the flow of molten alloy, and improve wetting between the alloy and the base metals.
Step 3: Assembly
The parts to be brazed are properly aligned and held in place, either by fixturing or using mechanical means such as clamps or jigs.
Step 4: Applying Heating
The area near the joint is heated to a temperature higher than the melting point of the brazing alloy but lower than the melting points of the base metals. In this step, capillary motion allows the brazing alloy to melt and flow into the junction. Manufacturers can choose from a variety of heating methods, such as torches, induction heating, and furnaces.
Step 5: Cooling
The heated joint is allowed to cool for some time.
As the brazing alloy melts, capillary action enables the alloy to enter the tiny gap between the base metals and fill it completely. The alloy wets the metal surfaces as it fills the area, producing a metallurgical bond. After allowing the joint to cool, we can see complete solidification and bond creation.
Brazing has recently become essential in producing durable equipment ranging from automobiles to aeroplanes. However, very little is known about the procedure and the products even to those who are certified brazers. In order to make the joint truly durable, there are multiple parameters one must consider. For example, is the filler metal compatible with the base metals? What are the properties of the resulting bond? Is the filler metal appropriate for the temperatures or pressures this component might be subjected to?
Even though the brazed joint is a minor and inconsequential component of a new refrigerator, air conditioner, or car for the average consumer, it is one of the most crucial aspects of the machine. Therefore, we at Mathure Metal Works Pvt. Ltd., the industry's top manufacturer, strive to not only manufacture high-quality brazing alloys that enable businesses to create innovative and durable products but also suggest the most optimum solutions. As a result, over the span of 50 years, we have seen the significant real-world impact our brazing alloys have had in the production of dependable cars, the advancement of HVAC systems, the empowerment of electronics, and the improvement of medical devices.
At Mathure Metal Works, we are ready to be your partner in brazing! Our team of alloy designers is skilled and ready to help you navigate this intricate world of brazing.