BRAZING, SOLDERING, AND

ADHESIVE BONDING

1. Brazing
g
2. Soldering
3. Adhesive bonding

©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
 Overview of Brazing and Soldering

ƒ Both use filler metals to p

permanently y jjoin metal p
parts,,
but there is no melting of base metals R1
ƒ Use brazing or soldering over fusion welding when:
ƒ Metals have poor weldability
ƒ Dissimilar metals are to be joined
j
ƒ Intense heat of welding may damage components
ƒ Geometryy of jjoint not suitable for welding g
ƒ High strength is not required
R2; SSW와 다른점은 Filler가 필요.
필요
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
 Overview of Adhesive Bonding

ƒ Uses forces of attachment between a filler material

and two closely-spaced surfaces to bond the parts
ƒ Filler material in adhesive bonding
g is not metallic
ƒ Joining process can be carried out at room
temperature or only modestly above

©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
 Brazing

Joining
gp process in which a filler metal is melted and
distributed by capillary action between faying
surfaces of metal parts being joined
ƒ No melting of base metals occurs
ƒ Only the filler melts
ƒ Filler metal Tm is greater than 450°C (840°F)
ƒ But less than Tm of base metal(s) to be joined

©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
 Strength of Brazed Joint

ƒ If jjoint is p
properly
p y designed
g and brazing g operation
p is
properly performed, solidified joint will be stronger
than the filler metal out of which it was formed
ƒ Why? R4
ƒ Small part clearances used in brazing
ƒ Metallurgical bonding occurs between base and
filler metals
ƒ Geometric constrictions imposed on joint by
base parts
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
 Brazing Compared to Welding

ƒ Anyy metals can be jjoined,, including

g dissimilar metals
ƒ Can be performed quickly and consistently,
permitting high production rates
ƒ Multiple joints can be brazed simultaneously
ƒ Less heat and p power required
q than FW
ƒ Problems with HAZ in base metal are reduced
ƒ Joint areas that are inaccessible byy manyy weldingg
processes can be brazed
ƒ Capillary action draws molten filler metal into joint
R7 ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
 Disadvantages and Limitations of
Brazing R11

ƒ Joint strength
g is g generally y less than a welded jjoint
ƒ Joint strength is likely to be less than the strength of
the base metals
ƒ High service temperatures may weaken a brazed
joint
ƒ Color of brazing metal may not match color of base
metal parts
ƒ A possible aesthetic disadvantage

©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
 Brazing Applications

ƒ Automotive ((e.g.,
g , jjoining
g tubes and p pipes)
p )
ƒ Electrical equipment (e.g., joining wires and cables)
ƒ Cutting tools (e.g., brazing cemented carbide inserts
to shanks)
ƒ Jewelryy
ƒ Chemical process industry
ƒ Plumbing g and heating g contractors jjoin metal p
pipes
p
and tubes by brazing
ƒ Repair and maintenance work
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
 Brazed Joints

ƒ Butt and lapp jjoints common R5

ƒ Geometry of butt joints is usually adapted for
brazing
g
ƒ Lap joints are more widely used, since they
provide larger
p g interface area between p parts
ƒ Filler metal in a brazed lap joint is bonded to base
parts throughout entire interface area, rather than
only at edges

©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
 Butt Joints for Brazing R6

ƒ (a)
( ) Conventional butt jjoint,, and adaptations
p for
brazing: (b) scarf joint, (c) stepped butt joint, (d)
increased cross section of the part at the joint

©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
 Lap Joints for Brazing

ƒ (a)
( ) Conventional lap p jjoint,, and adaptations
p for brazing:
g
(b) cylindrical parts, (c) sandwiched parts, and (d) use
of sleeve to convert butt joint into lap joint

©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
 Some Filler Metals for Brazing

Base metal(s)
( ) Filler metal(s)
( )
Aluminum Aluminum and silicon
Nickel-copper
Nickel copper alloy Copper
Copper Copper and phosphorous
Steel, cast iron Copper and zinc
Stainless steel Gold and silver

R10 Braze welding is used for adding braze metal to a more conventional geometry weld joint, such as
a V-joint. It differs from the typical brazing operation in that no capillary action occurs. It differs from
a conventional weldingg operation
p in that no melting
g of the base metals occurs.

©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
 Desirable Brazing Metal
Characteristics

ƒ Melting
g temperature
p of filler metal is compatible
p with
base metal
ƒ Low surface tension in liquid phase for good
wettability
ƒ High fluidity for penetration into interface
ƒ Capable of being brazed into a joint of adequate
strength for application
ƒ Avoid chemical and physical interactions with base
metal (e.g., galvanic reaction)

©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
 Brazing Fluxes

ƒ Similar p
purpose
p as in welding;
g; they
y dissolve,, combine
with, and otherwise inhibit formation of oxides and
other unwanted byproducts in brazing process
ƒ Characteristics of a good flux include: R8
ƒ Low melting temperature
ƒ Low viscosity so it can be displaced by filler
metal
ƒ Facilitates wetting
ƒ Protects joint until solidification of filler metal
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
 Applying Filler Metal

ƒ Several techniques
q for applying
pp y g filler metal in brazing:
g
(a) torch and filler rod: (1) before, and (2) after

©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
 Applying Filler Metal

ƒ More techniques for applying filler metal: (b) ring of

filler metal at entrance of gap: (1) before, and (2) after

©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
 Heating Methods in Brazing

ƒ Torch Brazing g - torch directs flame against

g work in
vicinity of joint
ƒ Furnace Brazing - furnace supplies heat
ƒ Induction Brazing – heating by electrical resistance to
high-frequency current in work
ƒ Resistance Brazing - heating by electrical resistance
in parts
ƒ Dip Brazing - molten salt or molten metal bath R9
ƒ Infrared Brazing - uses high-intensity infrared lamp
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
 Soldering

Joining
gp process in which a filler metal with Tm less than
or equal to 450C (840F) is melted and distributed by
capillary action between faying surfaces of metal
parts being joined
ƒ No melting of base metals, but filler metal wets and
combines
bi with
ith b
base metalt l tto fform metallurgical
t ll i l b bond
d
ƒ Filler metal called solder
ƒ Closely
Cl l associated
i t d with
ith electrical
l t i l assembly bl

©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
 Soldering Advantages and
Disadvantages
Advantages:
g R14
ƒ Lower energy than brazing or fusion welding
ƒ Variety of heating methods available
ƒ Good electrical and thermal conductivity in joint
ƒ Easy repair and rework

Disadvantages: R15
ƒ Low joint strength unless reinforced mechanically
ƒ Joint weakens or melts at elevated temperatures
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
 Mechanical Techniques to
Secure Joint

ƒ (a)
( ) Crimped
p lead wire on PC board; ((b)) p plated through-hole
g
on PC board to increase solder contact surface; (c) hooked
wire on flat terminal; and (d) twisted wires

©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
 Solders

Traditionallyy alloys
y of tin and lead ((both have low Tm)
ƒ Lead is poisonous and its percentage is minimized in
most solders
ƒ Tin is chemically active at soldering temperatures
and promotes wetting action for successful joining
ƒ In soldering copper, copper and tin form
intermetallic compounds that strengthen bond
ƒ Silver and antimony also used in soldering alloys

©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
 Soldering Fluxes: Functions

ƒ Be molten at solderingg temperatures

p
ƒ Remove oxide films and tarnish from base part
surfaces
ƒ Prevent oxidation during heating
ƒ Promote wettingg of faying
y g surfaces
ƒ Be readily displaced by molten solder during process
ƒ Leave residue that is non-corrosive and
nonconductive

©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
 Soldering Methods

ƒ Manyy soldering
g methods same as for brazing,
g, except
p
less heat and lower temperatures are required
ƒ Additional methods:
ƒ Hand soldering – manually operated soldering
gun
ƒ Wave soldering – soldering of multiple lead wires
in printed circuit cards
ƒ Reflow soldering – used for surface mount
components on printed circuit cards
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
 Wave Soldering R13

ƒ Molten solder is delivered up

p through
g a narrow slot
onto the underside of a PCB to connect the
component lead wires

©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
 Adhesive Bonding

Joining
gpprocess in which a filler material is used to hold
two (or more) closely-spaced parts together by
surface attachment
ƒ Used in a wide range of bonding and sealing
applications for joining similar and dissimilar
materials
t i l suchh as metals,
t l plastics,
l ti ceramics,
i wood,d
paper, and cardboard
ƒ Considered a growth area because of opportunities
for increased applications

©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
 Terminology in Adhesive Bonding

ƒ Adhesive = filler material,, nonmetallic,, usuallyy a

polymer
ƒ Adherends = parts being joined
ƒ Structural adhesives – of greatest interest in
engineering, capable of forming strong, permanent
joints between strong, rigid adherends
R16

©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
 R17
Curing in Adhesive Bonding

Process byy which physical

p y p
properties
p of the adhesive
are changed from liquid to solid, usually by chemical
reaction, to accomplish surface attachment of parts
ƒ Curing often aided by heat and/or a catalyst
ƒ If heat is used, temperatures are relatively low
ƒ Curing takes time - a disadvantage in production
ƒ Pressure sometimes applied between parts to
activate bonding process
R18
©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
 Joint Strength

ƒ Depends
p on strength
g of ((1)) adhesive and ((2))
attachment between adhesive and adherends
ƒ Attachment mechanisms:
ƒ Chemical
C bonding – adhesive and adherend form
f
primary bond on curing
ƒ Physical interactions - secondary bonding forces
between surface atoms
ƒ Mechanical interlockingg - roughness
g of adherend
causes adhesive to become entangled in surface
asperities

©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
 Joint Design

ƒ Adhesive jjoints are not as strong

g as welded,, brazed,,
or soldered joints
ƒ Joint contact area should be maximized
ƒ Adhesive joints are
ƒ Strongest
g in shear and tension loads
ƒ Weakest in cleavage or peeling
ƒ Design
g jjoints so that shear and tension loads
are applied but not cleavage and/or peeling

©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
 Types of Stresses in Adhesive
Bonding
ƒ Stresses in adhesive bonded jjoints: ((a)) tension,, ((b))
shear, (c) cleavage, and (d) peeling

©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
 Joint Designs in Adhesive
Bondingg

ƒ Joint designs:
g ((a)) through
g ((d)) butt jjoints;; ((e)) through
g ((f))
T-joints; (b) and (g) through (j) corner joints

©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
 Adhesive Types R19

ƒ Natural adhesives - derived from natural sources,,

including gums, starch, dextrin, soya flour, collagen
ƒ Low-stress applications: cardboard cartons,
furniture, bookbinding, plywood
ƒ Inorganic adhesives - based principally on sodium
silicate and magnesium oxychloride
ƒ Low cost, low strength
ƒ Synthetic adhesives - various thermoplastic and
thermosetting polymers

©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
 Synthetic Adhesives

ƒ Most important
p category
g y in manufacturing
g
ƒ Synthetic adhesives cured by various mechanisms:
ƒ Mixing catalyst or reactive ingredient with
polymer prior to applying
ƒ Heating
ea g to o initiate
a e cchemical
e ca reaction
eac o
ƒ Radiation curing, such as UV light
ƒ Curing by evaporation of water
ƒ Films or pressure-sensitive coatings

©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
 Applications of Adhesives

ƒ Automotive,, aircraft,, building

g products,
p , shipbuilding
p g
ƒ Packaging industries
ƒ Footwear
ƒ Furniture
ƒ Bookbinding
ƒ Electrical and electronics

©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
 Surface Preparation R20

ƒ For adhesive bondingg to succeed,, ppart surfaces must

be extremely clean
ƒ Bond strength depends on adhesion between adhesive
and adherend, which depends on clean surfaces
ƒ For metals, solvent wiping often used for cleaning,
and sandblasting improves surface adhesion
ƒ For nonmetallic parts, surfaces can be mechanically
abraded
b d d or chemically
h i ll etched
t h d tto iincrease roughness
h

©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
 Application Methods

ƒ Manual brushingg and rolling

g
ƒ Silk screening
ƒ Flowing, using manually operated dispensers
ƒ Spraying
ƒ Automatic applicators
ƒ Roll coating

©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
 R22
Advantages of Adhesive Bonding

ƒ Applicable
pp to a wide varietyy of materials
ƒ Bonding occurs over entire surface area of joint
ƒ Low temperature curing avoids damage to parts
being joined
ƒ Can be used for sealing g as well as bonding g
ƒ Joint design is often simplified, e.g., two flat surfaces
can be joined without providing special part features
such as screw holes

©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes
 R23
Limitations of Adhesive Bonding

ƒ Joints g
generally
y not as strong
g as other jjoiningg methods
ƒ Adhesive must be compatible with materials being
joined
ƒ Service temperatures are limited
ƒ Cleanliness and surface p preparation
p p
prior to application
pp
of adhesive are important
ƒ Curing times can limit production rates
ƒ Inspection of bonded joint is difficult

©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes