http://www.silfos.com/htmdocs/product_support/how_to_info.html The Brazing Process - Six Basic Steps 1.

Good Fit And Proper Clearance The best clearance between the two metal parts being brazed is a close one usually .001" to .003", and generally not more than .005". If the clearance is smaller than .001", there may be no room for the molten filler metal to flow through the joint. And if the clearance is wider than .005" or .006", capillary action is less effective and the filler metal may fail to fill the joint completely.

In the fabrication of HVAC equipment, achieving the proper clearance for brazed joints is seldom a problem. The design of the joint is predetermined it's almost always a "cup" design, in which one tube is inserted into the expanded end of another tube. As long as you start with tubing that's round and manufactured to the correct dimensions, you can anticipate no clearance problems.

A well brazed joint begins with a proper fit between components, .001".003" of clearance. 2. However, you do have to give some care to the preparation of the tubes for brazing. For example, if you're brazing a tube to a fitting, you'll generally start by cutting the tube to the length you want. Make sure it's cut square, by using a sawing vise or tube cutter, and remove the burrs. Slide the tube end into the fitting and check that it has the proper close fit an easy slip fit.

The majority of brazed joints HVAC units are copper-to-copper joints. That means you don't have to worry about the "coefficients of expansion" of the base metals as the two copper parts will expand at the same rate. However, if you're brazing joints of dissimilar metals (copper to steel) you have to take into consideration the different expansion rates. You know that non-ferrous metals (copper, brass) expand more during heating than ferrous ones (steel, stainless steel). So, be sure to adjust the initial joint clearance accordingly. Where heating will reduce the clearance, for example brazing a copper tube to a steel header, start with a relatively loose fit (approx. .010"). Where heating will increase the clearance, start with a close or even force fit.

3.

Cleaning The Metals Capillary action, the basis of all brazing, can't work properly on dirty surfaces. If the surfaces of the metals are contaminated (with oils, dirt, etc.) the brazing filler metals will not adhere to them and the joint will fail.

In fabricating HVAC units, you're generally working with factory new tubing and parts. But if for any reason those parts have become dirty or greasy, you will have to clean them to insure a leak tight joint. Oil and grease can be removed with a solvent, then oxides can be removed by an abrasive like an emery cloth. Once the parts are clean, it's recommended to braze as soon as possible so the parts won't have time to become re-contaminated. 4. Fluxing The Parts Flux is a chemical compound, usually made in the form of a liquid or paste which is applied to the joint surface prior to brazing. Its purpose is to protect the joint surface from the oxides that form during heating. Flux melts and becomes active during brazing, absorbing oxides and assisting in the flow of the brazing alloy. Although fluxing is generally an important part of the brazing process, it plays only a minor role in brazing HVAC components because most of these joints are copper-tocopper. When brazing copper-to-copper you can eliminate the flux by using a phosphorus bearing filler metal like Sil-Fos or Fos Flo because the phosphorus acts as a fluxing agent.

However, when brazing copper to steel (in compressor or valve assemblies) you can't use phosphorus bearing filler metals as they form brittle phosphides and the joint could fail. Instead use a phosphorusfree filler metal (like the Braze family of alloys) but then you will have to use a flux. When brazing brass, you could use a phosphorus bearing alloy, but you will have to apply flux here as well.

5.

Flux can be applied on to the parts being brazed with a brush, or it can be incorporated directly into the filler material in the form of flux cored or flux coated wire or rod. However the flux is applied, it is important that it does not get inside the parts where it could contaminate the system.

6.

Assemble For Brazing Before the parts can be heated and brazed, they have to be aligned and then supported. This is typically not an issue when brazing HVAC components since virtually all the joints are tubular, slip-fit assemblies. By their nature, they are self-aligning and self-supporting during the brazing process.

When assembling, make sure there is full insertion of one tube into the other before brazing. The distance of insertion should be equal to the inside diameter of the inner tube section.

A reducing flame is recommended when brazing 7. Brazing The Assembly

The actual brazing operation is a two-part process: first, heating the base metals and second, applying the filler metal to the joint.

Regardless of the heating equipment being used, be sure to heat both base metals broadly and evenly, so the filler metal will wet equally well on both metal surfaces and completely fill the joint. Because of the wide variety of joints and joint locations, the gas-air torch is frequently used as the heat source. A soft flame provides the best type of heat.

When brazing a tube to a fitting, or into another tube of larger diameter, the following procedures should be followed: Adjust the torch for a reducing flame (one that contains more fuel gas than oxygen). The flame should be soft enough and large enough to envelop both the tube and fitting. Bring both pieces being brazed up to temperature Start heating the tube about an inch away from the end of the fitting, then shift the heat to the fitting. Sweep the heat steadily back and forth from tube to fitting, with most of the heat being applied to the heavier (and slower to heat) fitting. evenly and quickly

Heat the assembly until it reaches brazing temperature. If the part has been fluxed with Handy Flux, the flux will become clear or transparent at this temperature. If you have not used flux, you'll know you're at brazing temperature by the dull red color of the metals being heated.

At this point, pull the flame back a little and apply the filler metal firmly against the tube at the junction of the tube and fitting. If you are using a phosphorus-bearing alloy, lay the rod

on and wipe it around the joint, as these alloys tend to flow sluggishly. If the joint has been properly heated, the filler metal will melt, penetrate and completely fill the joint. Once the assembly has reached brazing temperature the filler After the joint has been completed, make one final pass of the flame at the base of the joint, and even twist the joint if possible, to expel any entrapped gas or flux and to provide maximum wetting by the filler metal. metal is applied.

A well brazed joint Proper alloy flow reaches inside the joint

Improper alloy flow does not penetrate into the joint and produces a weak bond. 8. Cleaning the Brazed Joint Generally speaking, brazed joints in HVAC units require no post braze cleaning operations. However, in the minority of cases where flux has been used, it may be necessary to remove the flux residues after the joint has set. A hot water wash, assisted by brushing or swabbing usually does the job. If necessary, you can remove more stubborn residues with a wire brush.

Some Things To Consider

When you're heating an assembly for brazing, you want to heat the joint area as rapidly and as uniformly as possible. So in those instances where you're joining metals of unequal mass and thickness you'll have to apply some extra heat to the heavier section which heats more slowly. And where you're joining dissimilar metals with differing heat conductivity (copper to steel), you'll have to apply proportionally more heat to the copper, since copper is a better conductor and carries heat away more rapidly to the colder sections. In no case, of course, should the metals be heated to the point where they begin to melt.

Three Common Joints

The brazing techniques described will vary somewhat depending upon the kind of joint you're making. The three common tube-to-fitting joints used in HVAC components are the vertical down, the vertical up and the horizontal joint. The following procedures are recommended for each of these joints:

Vertical down joints: Bring the entire joint area up to temperature quickly and uniformly, heating the tube first, then the fitting. When the joint area has reached brazing temperature, apply a little extra heat to the fitting, since this is the direction in which you want the filler metal to flow.

Vertical up joints: Start by heating the tube. When it has reached a temperature of about 800 F (425 C) transfer the heat to the fitting. Then sweep back and forth from fitting to tube, all around the joint area. Be careful not to overheat the tube below the fitting, as this would encourage the filler metal to run down the tube and out of the joint. When brazing temperature is reached, touch the filler metal to the joint with the flame on the wall of the fitting. This heating pattern will draw the filler metal up and completely through the joint area.

Horizontal joints: Preheat the tubing and fitting quickly and evenly. When brazing temperature is reached, apply the filler metal to the top of the joint. The combination of gravity and capillary action will draw the filler metal completely around the tube to its bottom. You can apply a slight excess heat to the bottom of the fitting to insure that the filler metal totally penetrates the joint. Check the joint face to be sure filler metal is visible all around it. In particular, make sure that filler metal shows at the top of the joint. If it does not, apply some additional filler metal until it is visible all around the joint.

http://www.aws.org/wj/amwelder/9-00/fundamentals.html Understanding Brazing Fundamentals

By clearly understanding the process, its fundamentals and how to apply them, brazing with a silvercontaining filler metal can be cost effective and reliable By Alan Belohlav

Most of us have, at some time, seen brazing with a silver-containing filler metal, commonly called "silver brazing," used somewhere in a manufacturing or maintenance environment. You may have wondered, "Why do this kind of brazing? Why don't they just weld it, fasten it or even glue it?" The answer is, brazing with a silver-containing filler is one of the most versatile methods of metal joining in use today, for a number of reasons. It is cost-effective. There is very little braze alloy required to produce a brazed joint. With properly designed joints, this kind of brazing will compare favorably with any other metal joining method.

 The joints produced are strong. Engineers and designers frequently request strength data of brazing filler metals, making the assumption the brazed joint will only be as strong as the brazing filler metal itself. Surprisingly, depending on the base material, properly made brazed joints will exhibit tensile strengths far greater than the filler metal. Typically, braze-joint strength is closer to the yield strength of the base metal being joined. As an example, the filler metal BAg-1 has a tensile strength of 50 ksi. As shown in Fig. 1, 18-8 stainless steel joints brazed with BAg-1 have tensile strengths in excess of 120 ksi, far greater than the filler metal itself. The joints produced are ductile, able to withstand considerable shock and vibration. The joints are generally produced easily and quickly. It can join dissimilar metals well. You can easily join metals with widely different melting points. It can join metals with vastly different cross sections. For example, joining 0.005-in.-thick copper foil to a 1-in.-thick steel plate would be a challenge to weld, but relatively easy to braze. Joints have excellent stress distribution and heat transfer. The braze fillet formed is ideally shaped to resist fatigue. It is highly adaptable to automation. Typical automation methods include torch, furnace, induction and resistance heating. It is essentially a one-operation process. There is seldom any need for grinding, filing or mechanical finishing after the joint is completed. This is particularly beneficial for assemblies to be plated. The joints virtually make themselves by capillary action, so complex geometries are as easy to join as simple geometries.

The Process
Commonly referred to as silver brazing, the process uses a silver-containing alloy with a melting temperature above 840F (450C) but below the melting point of the metals to be joined. In brazing, the base metals are heated, usually to a point slightly above the liquidus (flow point) of the filler metal, causing it to melt. The filler metal then flows into the parallel joint clearance between the two base materials by capillary attraction and bonds to their surfaces through atomic attraction and diffusion. Unlike other methods of metal joining, such as braze welding and welding wherein the filler metal is applied in quantity and generally in the form of fillets, in brazing we are interested in flowing the alloy between closely fitted members. To effectively braze with a silver-containing filler metal, one must clearly understand brazing fundamentals. Most problems associated with brazing are the result of one or more of the brazing fundamentals being violated. When brazing fundamentals are understood, problem solving becomes a simple matter of the process of elimination. These fundamentals include the following: Good fit and proper clearance Clean base metals Proper fixturing Proper fluxing/atmosphere Heating the assembly Cleaning the brazed assembly.

Good Fit and Proper Clearance

A braze alloy relies on capillary action to distribute the brazing filler metal throughout the joint interface. Capillary action is the force that pulls a liquid through two parallel surfaces. In brazing, the clearance at which capillary action is most effective is in the 0.001- to 0.005-in. range.

Joint clearance also has a profound impact on joint strength. Figure 2 shows how the tensile strength of a stainless steel brazed joint varies with the amount of clearance between the parts being joined. Note that the strongest joint (135,000 lb/in.2 [930.8 MPa]) is achieved when the joint clearance is 0.0015 in. (0.038 mm). When the clearance is narrower, it is difficult for the filler metal to distribute itself adequately throughout the entire joint, reducing joint strength. Conversely, if the joint clearance is wider than necessary, the strength of the joint will be reduced almost to that of the filler metal itself. Translated into everyday shop practice - an easy slip fit will give you a perfectly adequate brazed joint between two tubular parts. And, if you are joining two flat parts, you can simply rest one on top of the other. The metal-to-metal contact is all the clearance you will usually need, since the average "mill finish" of metals provides enough surface roughness to create capillary "paths" for the flow of molten filler metal. Highly polished surfaces, on the other hand, tend to restrict filler metal flow. There are, of course, certain factors affecting clearance that need consideration, particularly as it applies to tubular members. For example, when brazing a brass bushing into a steel sleeve (Fig. 3), consider that the brass has a greater coefficient of expansion than the steel. And, as it is to be the inner member of the assembly, you must allow a greater clearance than if both pieces were steel. By the same premise, if the position of the parts were reversed - the brass becoming the outer member and the steel the inner - you probably would want to allow a little less clearance than if both parts were of the same material. In general, clearances should be considered in light of the parts at brazing temperature rather than at room temperature.

Cleaning the Metals

Capillary action will work properly only when the surfaces of the metals are clean. Contaminants, such as oil, grease, rust, scale or plain dirt, must be removed. If they remain, they will form a barrier between the base metal surfaces and the brazing materials. An oily base metal, for example, will repel the flux, leaving bare spots that oxidize under heat and result in voids. Oil and grease will carbonize when heated, forming a film over which the filler metal will not flow. Start by getting rid of oil and grease, usually done easily by dipping the part into a suitable degreasing solvent, or by vapor degreasing, alkaline or aqueous cleaning. If the metal surfaces are coated with oxide or scale, you can remove those contaminants chemically or mechanically. For chemical removal, use an acid pickle treatment, making sure the chemicals are compatible with the base metals. Mechanical removal calls for abrasive cleaning. Particularly in repair brazing, where parts may be very dirty or heavily rusted, you can speed the cleaning process by using emery cloth, a grinding wheel, file or metallic shot blast.<> Once the parts are thoroughly clean, it is a good idea to flux and braze as soon as possible. That way, there is the least chance for recontamination of surfaces by factory dust or body oils deposited through handling.

Fluxing the Parts

Flux is a chemical compound applied to the joint surfaces before brazing. Its use is essential for brazing (with a few exceptions noted later). The reason? Heating a metal surface accelerates the formation of oxides, the result of chemical reactions between the hot metal and oxygen in the air. These oxides have to go, or they will prevent the brazing filler metal from wetting and bonding to the surfaces. A coating of flux on the joint area, however, will shield the surfaces from the air, preventing oxide formation. The flux will also dissolve and absorb any oxides that form during heating or that were not completely removed during the cleaning process. Since flux conventionally comes in a paste, it is usually most convenient to brush it on. For large quantities, it may be more efficient to apply the flux by dipping or by using a low-viscosity dispensable flux sprayed from a gun. Flux the assembly just before brazing, if possible. There are fluxes formulated for practically every need -fluxes for brazing at very high temperatures (i.e., 2000F), fluxes for metals with refractory oxides, fluxes for long heating cycles, dry flux powders and fluxes for

dispensing by automated machines. As a general rule, do not skimp on the flux. It is your insurance against oxidation. Think of the flux as a sort of blotter. It absorbs oxides like a blotter absorbs ink; too small an amount of flux will quickly become saturated and lose its effectiveness. A flux only mildly loaded with oxides will not only ensure a better joint than a totally saturated flux, but it is a lot easier to wash off after the brazed joint is completed. Flux also acts as a temperature indicator, minimizing the chance of overheating. White lowtemperature silver brazing flux, for example, becomes completely clear when active at 1100F. At this temperature it looks like water and reveals the bright metal surface underneath - telling you the base metal is just about hot enough to melt the brazing filler metal. While fluxing is usually an essential step in the brazing operation, there are a couple of exceptions to the rule. You can join copper to copper without flux by using a brazing filler metal specially formulated for the job, such as silver-copper-phosphorus alloys. The phosphorus in these alloys acts as a fluxing agent on copper. Also, you can often omit fluxing if you are going to braze the assembly in a controlled atmosphere -a gaseous mixture contained in an enclosed space, usually a brazing furnace. The atmosphere (usually hydrogen, nitrogen or argon) completely envelops the assemblies and, by excluding oxygen, prevents oxidation. Even in a controlled atmosphere, however, a small amount of flux may improve the wetting action of the brazing filler metal.

Proper Fixturing
If the shape and weight of the part permit, the simplest way to hold them together is by gravity. Or you can add additional weight. If you have a number of assemblies to braze and their configuration is too complex for self-support or clamping, it may be a good idea to use a brazing support fixture. In planning such a fixture, design it for the least possible mass;contact area between the fixture and the assembly should be at a minimum - Fig. 4. A fixture that contacts the area broadly will conduct heat away from the joint area. If the fixture is to be used in a torch application, be sure to allow clearance for the open flame to reach the joint area without restriction. Choose materials that are resilient to high temperature and thermal cycling, such as stainless steel, Inconel or ceramics. If you need to fixture close to the joint, where you risk brazing the assembly to the fixture, use a nonwetting material, such as titanium. However, if planning to braze hundreds of identical assemblies, consider designing the parts themselves so they are self-supporting during the brazing process. Typical methods of self-support are crimping, interlocking, swaging, peening, riveting, pinning, dimpling or knurling - Fig. 5.

Heating the Assembly

This step brazes the joint. It involves heating the joint to brazing temperature and flowing the filler metal through the joint. Both metals in the assembly should be heated as uniformly as possible so they reach brazing temperature at the same time. Therefore, when joining a thick section to a thin section, more heat should be applied to the thick section. Or, when joining a good conductor of heat to a poor conductor, such as copper to stainless steel, more heat will have to be applied to the good conductor (in this case, the copper) simply because they dissipate the heat more rapidly. In all cases, your best insurance against uneven heating is to keep a watchful eye on the flux. If the flux changes in appearance uniformly, the parts are being heated evenly, regardless of the difference in their mass or conductivity. In manual brazing, when the assembly reaches brazing temperature, hold the brazing rod carefully against the joint area. Do not heat the brazing rod directly. The heated assembly will melt off a portion of the braze rod, which will instantly be drawn by capillary action throughout the entire joint area. This technique ensures the assembly is at braze temperature and helps to prevent cold joints.

Take care, however, because molten brazing filler metals tend to flow toward areas of higher temperature. In the heated assembly, the outer base metal surfaces may be slightly hotter than the interior surfaces. So take care to deposit the filler metal immediately adjacent to the joint. If you deposit it away from the joint, the filler metal tends to plate over the hot surfaces rather than flow into the joint. It is best to heat the side of the assembly opposite the point where you are going to feed the filler metal - Fig. 6. If using preforms - slugs, washers, shims or special shapes of filler metal preplace them in the joint before applying heat to the assembly.

Cleaning the Brazed Assembly

Postcleaning of brazed assemblies is done primarily to remove flux residue. Flux removal is a simple, but essential, operation for one reason. Flux residue is corrosive and if not removed can attack the base metal or braze filler metal, possibly weakening the joint. Since most fluxes are water soluble, the easiest way to remove them is to submerse the assembly in hot water (150F or hotter). You can use more elaborate methods of removing flux as well, such as an ultrasonic cleaning tank to speed the action of the hot water. Or, if the assembly is too large to submerse in hot water, hotpressure washing or live steam may be viable options. Quenching the assembly in hot water will crack the flux off and expedite the flux removal procedure. However, avoid quenching assemblies having base metals with large differences in coefficient of expansion (such as tungsten carbide to steel) or assemblies with vastly different cross sections; otherwise, the base metal or joint may fracture. When in doubt, allow the assembly to cool slowly to ambient temperature before submersing it in water. After removing the flux, you can remove residual oxides by acid pickling or mechanical cleaning.

Conclusion
Brazing with silver-containing filler metal is an effective means of creating strong, leaktight joints on a diverse group of base metals. By clearly understanding the process, its fundamentals and how to apply them, it can be a cost-effective and reliable method of manufacturing metal-to-metal joints.