No.

of the Experiment : 04
Name of the Experiment : Study of Soldering and Brazing Operation.

Objectives :
1. To compare the structural integrity and strength of joints formed through
soldering and brazing techniques.
2. To analyze the thermal properties and melting points of different filler
materials used in soldering and brazing.
3. To evaluate the impact of various fluxes on the quality and durability of
soldered and brazed joints.

Theory :
Soldering is a semi permanent joining process where two or more metal parts are
bonded together by melting a filler metal, called solder, which has a melting point
below 840°F. Brazing is similar to soldering but involves a higher temperature,
typically above 840°F. Soldering and brazing are different from welding because in
these processes, the melting of base metals is not involved.
Soldering : This process is usually done between 350F-600F. In this range, the
filler material melts, but the base metal doesn't.
Soldering process is can be broken down into 4 steps, the first 3 being prework.
The steps are :
1. Metal cleaning : In this step, the metal parts are inspected for defects, such
as cracks, dents, or deformations, and they are cleaned and dried to remove
contaminants, such as oxide, dirt, grease, or oil.
2. Oxide film formation : After cleaning, the metal reacts with the oxygen in the
air, which forms a thin oxide film on the outer surface of the metal parts.
3. Applying flux : In this step, flux is prepared, which is then applied to the
metal parts. This cleans and dissolves the oxide film which had formed earlier. It
increases the wetting ability of the solder, causing it to flow more uniformly over
surfaces without balling-up.
4. Soldering start : Finally, heat is applied and the main process of joining
metals begins.
Solders are usually lead and tin alloys, sometimes containing small amounts of
cadmium and antimony. Soldering process is mostly manual.
Brazing : This process is usually done between 1100F-1500F. Since higher
temperature is used, brazing creates stronger bond than soldering. So, thicker
metal parts can be joined in this process.
There are various types of brazing. The two main types are :
1. Torch Brazing : In this method, the heat required to melt and flow filler metal
is supplied by a fuel gas flame. It is very precise, so it can be done on small
parts. In fact, various shapes can be brazed in this method. The equipment used is
portable and handy. But, the batch size is usually limited. Aldo, in this method,
the process has to be done manually, so it cannot be automated. Since flux is used,
a clean-up necessary after brazing is complete.
2. Furnace Brazing : This process is done by placing solid filler metal where the
joint is required. Then, the jobpiece is placed in the furnace, where the filler
metal melts and flows into shape. This is how brazing is done in this method. Batch
size can be large when doing furnace brazing. The process can also be automated.
The temperature is controlled so that the base metal doesn't melt, but filler metal
does.
In this experiment, soldering and brazing processes were observed closely a
practical level.

Discussion :
Both soldering and brazing processes require some pre-work. Cleaning before
soldering and brazing is crucial because contaminants like dirt, grease, oxides,
and oils can prevent proper bonding between metals. Clean surfaces allow the solder
or brazing filler to flow and adhere properly, ensuring a strong, reliable joint.
Impurities can lead to weak connections, poor electrical conductivity, and
potential joint failure over time.
In soldering and brazing, capillary force draws molten filler metal into narrow
gaps, while surface tension controls its flow on the surface. A well-formed
meniscus indicates good wetting and proper bonding. Together, these factors ensure
the filler material flows evenly into joints, creating strong, reliable
connections.
Both soldering and brazing have advantages and disadvantages. Since temperature is
controlled to remain in a range where the base metal doesn't melt but the filler
metal does, there is not much metallurgical change in the base metal. Which means,
these processes keep the properties of the base metal intact. In both soldering and
brazing, dissimilar metals can be joined. Some molecules of the base metal creates
bonds with the filler material molecules and create solid solution. This makes the
joint strong. Soldering uses lower temperatures, making it suitable for delicate
components like electronics, with minimal thermal distortion, but results in weaker
joints. Brazing, on the other hand, involves higher temperatures and creates
stronger, more durable joints, ideal for larger or structural applications, though
it risks thermal distortion and requires more complex equipment. Both methods can
join dissimilar metals, but soldering is better for low-stress applications, while
brazing offers greater mechanical integrity.
Soldering is widely used in electronics for connecting circuit boards, wiring, and
delicate components due to its low-temperature process. It's also common in
plumbing for joining copper pipes and in jewelry making for delicate metalwork.
Brazing, with its stronger joints, is often applied in HVAC systems, automotive and
aerospace industries, and in joining metal components like pipes, rods, and
structural parts where high strength and durability are required. Both methods are
also used for repairing metal tools and equipment.
In conclusion, we can say that both soldering and brazing processes are very
important in various industries.