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Posts Tagged ‘Brazing’

Last week, an aluminum nozzle got hit and apparently got ruptured in my kitchen, causing a lot of inconvenience in work. So I had to get it replaced as quickly as possible, but there was no time to go out the next day and the nearby shops were closed due to a holiday. So I decided to get it repaired by calling a professional to repair leak, but no one was available on this end either. So I started making calls for Aluminum cracked repair specialists, but again, it seemed as if bad luck was hovering upon me that day, I couldn’t find anyone appropriate for a job. So I went to my neighbor to ask if they knew anyone or anything which could help me out as it was pretty urgent to fix the nozzle. Luckily, there was a guy sitting there who knew much about all these repairs, so he volunteered to look up. Overwhelmed, and hopeful, I led him into the kitchen where he just smirked as if the damage was so minor and anyone could fix it! He went back home and came back in a few minutes with a bag full of tools.

While he was on his work, I noticed he was using a very different kind of a rod, quite different than the other professionals I had seen using. I asked him why it looked so different, to which he replied that it was a special kind of a ‘brazing rod’ which made the work easier and faster. Another advantage to use it was that it made the metal more strong in comparison to other welding machines or rods. What more, it could also be used on alloys, you could also do brazing on other metals, for instance, it worked great for cast iron brazing etc.

A few points he told me about the whole welding-brazing process was that there should be a lot of cleanliness to be maintained in the process and one must make sure that no carbon is sticking around. Thus, it is pivotal to not only clean the entire surface, but brush it as well. Also, MIG welding or Metal Inert Gas welding is a great method in which inert gases (that is, the gases which don’t react with other gases) such as helium and argon are used; these gases act as a shield outside creating a protective atmosphere.

All this information was nice to learn while he did the job in a jiffy. I am also planning to take a few lessons! Self help works great!

Learn how to use the brazing rod to make wire figures, as an expert craftsman illustrates wire sculpting techniques in this free video art lesson. Expert: Mark Kooy Bio: Mark Kooy has been teaching high school students how to work with ceramics, metals, painting, drawing, and publications for over 20 years. Filmmaker: Tim Adams
Video Rating: 1 / 5

More Brazing Rod Articles

Brazing process exudes fumes, emissions and radiations that may be harmful for the people involved in conducting and managing. The people working in this industry are exposed to gases and harmful radiations that are exuded by the brazing of the base metals and the filler metals. The emissions can affect the workers, physically because of the sparking in the process and can cause respiration problems as well. Physically the body parts – nails, hair, eyes, skin – exposed to these sparking fumes and gases might get affected. Brazing safety measures should be adopted to combat these hazards.

To ensure complete working safety for the brazing workers, safety equipments have been developed. These equipments must be worn by the workers while conducting brazing. They save not just from the hazardous side effects, but also make it comfortable.

Leather Body Suit

A leather body suit is designed for people who are involved in bonding techniques like soldering, welding and brazing. It saves the body parts from sparks and heat caused by brazing. It is a made of non-flammable and heat resistant material. A body suit must be worn over the normal daily wear clothes for complete body protection.

Gloves

Gloves are not included in the body suit. And should therefore be separately arranged for and worn. Gloves are very important as your hands are the amongst those parts of the body to the that are closest to the brazing area. Leather gloves are again heat and fire resistant, and a must safety equipment.

Shoes

Just like gloves, shoes should also be made out a similar material. Apart from being close to the sparks, feet are also exposed to distant sparks flying down or any hot substances on the floor. Special shoe coverings keep the feet safe.

Brazing Glasses

Blazing glasses are also available, made out of special material for protecting the eyes from the harmful radiations produced by the excessive heating.

Helmet

Heat, radiation and chemicals fill the air in the surroundings and cause harm to the facial skin and hair. Inhaling of these gases is also harmful for our respiration system. It is advisable that every worker should wear helmets for complete protection through the process.

Related Brazing Equipment Articles

More Welders Resort to Induction Heating For Preheating, Stress-Relieving

Traditional Induction Heating Applications

- Soldering                                                          

- Brazing

- Surface hardening

- Tempering
- Bonding

- Curing                                                        
- Encapsulating
- Melting
- Forging
- Super heating
- Crystal growing

Although many industries have used induction heating for decades, it’s a newcomer to industrial and construction applications involving welding. Pre-heating before welding and stress-relieving (i.e. postheating) after welding are the new uses for induction heating, and companies with weldiang-intensive operations have significantly increased efficiency as a result.

Induction heating: how it works

Induction heating systems employ non-contact heating. They induce heat electromagnetically rather than using a heating element in contact with a part to conduct heat, as does resistance heating. Induction heating acts more like a microwave oven; the appliance remains cool while the food cooks from within.

In an industrial example of induction heating, heat is induced in the part by placing it in a high-frequency magnetic field. The magnetic field creates eddy currents inside the part, exciting the part’s molecules and generating heat. Because heating occurs slightly below the metal surface, no heat is wasted.

Induction heating’s similarity to resistance heating is that conduction is required to heat through the section or part. The only difference is the source of heat and the temperatures of the tool. The induction process heats within the part and the resistance process heats on the surface of the part. Depth of heating depends on the frequency. High frequency (e.g., 50 khz), heats close to the surface, while low frequency (e.g., 60 Hz) penetrates deeper into the part, placing the heating source up to 3 mm deep, allowing heating of thicker parts. The induction coil does not heat-up because the conductor is large for the current being carried. In other words, the coil does not need to heat-up to heat the workpiece.

Induction heating system components

Induction heating systems can be air- or liquid-cooled depending on application requirements. A key component common to both systems is the induction coil used to generate heat within the part.

Air-cooled system

A typical air-cooled system consists of a power source (5kW or 25kW), induction blanket, and associated cables. The induction blanket consists of an induction coil surrounded by insulation and sewn into a high temperature, replaceable Kevlar sleeve. This type of induction system can include a controller to monitor and automatically control temperature. A system not equipped with a controller requires the use of a temperature indicator. The system could also include a remote on-off switch. Air-cooled systems can be used for applications up to 400 degrees F, designating it as a pre-heat only system.

Liquid-cooled system

Because liquid cools more efficiently than air, this type of induction heating system can be used for applications requiring higher temperatures, such as high-temperature preheating and stress relieving. The principle differences are the addition of a water cooler and the use of a flexible liquid-cooled hose that houses the induction coil. Liquid-cooled systems also generally use a temperature controller and built-in temperature recorder, particularly important components in stress relieving applications. The typical stress relieving procedure requires a step to 600-800 degrees F, followed by a ramp or controlled temperature rise to a soak temperature of approximately 1250 degrees F. After a hold time, the part is control-cooled to between 600-800 degrees F. The temperature recorder collects data on the part’s actual temperature profile based on a thermocouple input, a QA requirement for stress relieving applications. The actual procedure will be determined by the type of work and the applicable code.

Induction heating benefits

Compared to conventional preheating and stress relieving methods, induction heating offers numerous advantages, including improved heat uniformity and quality, reduced cycle time, and lower consumables costs. Induction heating is also safe, reliable and easy to use, and scores higher than alternative technologies in power efficiency and versatility.

Uniformity and quality

Induction heating is not particularly sensitive to coil placement or spacing. Generally, the coils should be evenly spaced and centered on the weld joint. On systems so-equipped, a temperature controller can establish the power requirement in an analog fashion, providing just enough power to maintain the temperature profile. The power source provides power during the entire process.

Reduced cycle time

The induction method of preheating and stress relieving provides significantly quicker time-to-temperature. On thicker applications, such as high pressure steam lines, induction heating can slash two hours from cycle time. It is conceivable to reduce cycle time from the control temperature to soak temperature. When combined with other usability factors, it is not uncommon to expect a 50 percent total cycle time reduction.

Reduced consumables costs

The insulation used in induction heating is easy to attach to work pieces and can be reused many times. Conversely, ceramic fiber insulation used in resistance heating can be used only once or twice before it has to be discarded, requiring a large inventory of insulation and incurring significant costs for disposal of potentially hazardous material. In addition, in comparison to resistance system components, induction coils are robust and don’t require fragile wire or ceramic materials. Also, because the induction coils and connectors don’t operate at high temperatures, they are not subject to degradation, as are ceramic heating pads.

Ease-of-use

A major benefit of induction preheating and stress relieving is its simplicity, which contributes to easy use. Insulation and cables are simple to install, usually taking less than 15 minutes. http://inductionheater.net  has shown boilermakers and pipefitters how to use the induction equipment with just one day of training.

Power efficiency

The inverter power source is 92 percent efficient, a critical advantage in an era of skyrocketing energy costs. Additionally, the induction heating process is more than 80 percent efficient. Regarding power input, the induction process only requires a 40 amp line for 25kW of power.

Safety

Preheating and stress relieving through the induction method is extremely worker-friendly. Induction heating does not require hot heating elements and connectors. Very little airborne particulate is associated with the insulation blankets, and the insulation itself is not exposed to temperatures over 1800 degrees F, which can cause insulation to break down into dust and then breathed by workers .

Reliability

One of the most important factors impacting productivity in stress relieving is not interrupting the cycle. In most instances, cycle interruption means the heat treat will need to be re-run, which is significant when a thermal cycle can take a day to complete. The induction heating system components make cycle interruptions unlikely. The cabling for induction is simple, making it less likely to fail. Also, no contactors are used to control the heat input to the part.

Versatility

The Duolin Induction Heat Treatment System was originally designed for preheating and stress relieving of pipe. Now, users of induction heating systems have adapted the process for weldolets, elbows, valves, and other parts. One of the aspects of induction heating that makes it attractive for complex shapes is the ability to adjust the coils during the heating process to accommodate unique parts and heat sinks. The operator can start the process, determine the affects of the heating process in real-time and modify the coil position to change the result. Lastly, the induction cables can be moved without waiting for air cooling at the end of the cycle.

Induction heating in welding applications

DUO LIN Induction Heating Systems, Co, Ltd., the manufacturer of induction heating systems for welding applications, has proven its technology on a number of projects, including oil and gas pipelines, heavy equipment construction and maintenance and repair of mining equipment. Summaries of various projects are presented below.

Oil pipeline

A North American oil pipeline maintenance operation had used a combination of propane torches and electrical resistance to heat pipe before welding encirclement repair sleeves or STOPPLE fittings to the pipeline’s 48-inch girth. While many repairs could be made without having to stop oil flow or drain it from the pipe, the presence of the crude itself hampered welding efficiency due to the heat sink effect of the flowing oil. Propane torches required constant interruption of welding to maintain heat, and resistance heating – while providing continuous heat – often couldn’t meet required weld temperatures.

The maintenance company turned to induction heating as a solution. On encirclement sleeve repairs, two 25kW systems were employed with parallel blankets to obtain a preheat temperature of 125 degrees F. As a result, cycle time was reduced from 8-12 hours to 4 hours per girth weld. Preheating for a STOPPLE fitting (a “T” junction with valve) repair had been even more challenging due to the fitting’s greater wall thickness. With induction heating however, the company used four 25kW systems with a paralleled blanket set-up. Two systems were used on each side of the “T”. One system was used on the mainline to preheat the oil and the second was used to preheat the “T” at the circumferential weld joint. The preheat temperature was 125 degrees F. The weld time was reduced from 12-18 hours to seven hours per girth weld.

Natural gas pipeline

A natural gas pipeline construction project entailed building a 36 in. diameter, .633 in. pipeline from Alberta, Canada to Chicago. On one spread of this pipeline, the welding contractor used two 25kW power sources mounted on a tractor with the induction blankets attached to booms for speed and convenience. The power sources were used to preheat both sides of the pipe joint. Critical to this process was speed and reliable temperature control. As alloy content increases in materials to reduce weight and weld time, and to increase part life, controlling preheat temperatures becomes more critical. In this induction heating application, it required less than three minutes to obtain the 250 degrees F preheat temperature, versus approximately five minutes using traditional preheating methods. In addition, temperature uniformity and operator safety were improved.

Heavy Equipment

A heavy equipment manufacturer often welds adapter teeth onto its loader bucket edges. Previously, the tack welded assembly was moved back and forth to a large furnace, requiring the welding operator to wait while the part was reheated repeatedly. The manufacturer opted to try induction heating to preheat the assembly to prevent movement of the product. The material is 4 in. thick with a high required preheat temperature due to alloy content. Duolin Electric worked with the customer to develop customized induction blankets to meet the application requirements. The insulation and coil design provided the added benefit of shielding the operator from the part’s radiant heat. Overall, operations were considerably more efficient, reducing welding time and maintaining temperature throughout the welding process.

Mining equipment

A mine had been experiencing cold cracking problems and preheating inefficiency using propane heaters in its repair operations of mining equipment. Welding operators had to remove a conventional insulating blanket from the thick part frequently to apply heat and keep the part at the correct temperature. The mine opted to try induction heating using flat, air-cooled blankets to preheat the parts before welding. The induction process applied heat to the part quickly. It also could be used continuously during the welding process. Weld repair time was reduced by 50 percent. In addition, the power source was equipped with a temperature controller to keep the part at the target temperature. This virtually eliminated rework due to cold cracking. The customer reported an annual savings of ,000.

Power plant

A power plant builder was constructing a natural gas power facility in California. Boilermakers and pipefitters had been experiencing construction delays due to the preheating and stress relieving methods they were employing on the plant’s steam lines. One of the biggest problems on this job was reliability of the electrical resistance equipment, which suffered from contactor and connector failures and broken wires on the heating pads during stress relieving. Extensive rework as a result, combined with long heating cycles, was delaying construction significantly. The company brought in induction heating technology in an attempt to increase efficiency, particularly for work on medium to large steam lines, as these pieces take the most heat treating time required on a job site.

On a typical 16 in. weldolet with a 2 in. wall thickness, resistance preheating and stress relieving used to take five-and-a-half hours to complete. Induction heating was able to shave two hours off the time-to-temperature (600 degrees F) and another hour to reach soak temperature (600 degrees F to 1350 degrees F) for stress relieving. The simplicity of wrapping the induction blankets around complex shapes further reduced the time to perform the heat treat. It took the fitters 15 minutes to wrap a joint that would have required two workers two hours to prepare using a resistance set-up.

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Brazing refers to the joining of two metals. It is easy to do and substitute the welding part quite efficiently. It most often makes use of torches to join two metals. Propane torches are one such equipment which is popularly used for brazing. These can be easily sourced from any of the hardware store or a plumbing supply house. Metalsmith and jewelry supply firms too can provide propane torches. Mentioned below is the basic process of brazing two metals using a propane torch. Take a look:

Materials Needed

-Propane Torch
-Brazing Wire

Step 1
The very first step in propane brazing is to clean the metal that you plan to braze. For cleaning, one can make use of sandpaper to remove oxidation while acetone should be used to get rid of grease. Also, use simple soap and water solution to remove the remaining dust particles from the metal surface. Now once all the dirt and grease is removed from the metal, rinse it with water and let the clean metal air dry completely. It might take a time of few hours.

Step 2
Next, put the metal over a work surface which is fire-safe. Then arrange the metal to be brazed properly so that it does not move from the point it has been placed. One should make use of either binding wire, or a third hand or a vise for holding the two metals together as depending on gravity alone for handling the metal in place would not be a good idea.

Step 3
Now the next step in brazing process is to heat both the metals that you plan to join together. As soon as the metals arrive at the perfect brazing temperature, brazing wire needs to be applied to the seam. Keep heating the brazing wire till the time it melts into the seam.

Step 4
Lastly, let the metals cool down to the room temperature and you are already done with the brazing process using propane torch.

To know more about torch brazing, click here.

Brazing is an effective thermal joining process commonly used in engineering. It is often preferred over other process like welding. Brazing can join almost all the metals and alloys. In this process, a molten brazing alloy is drawn into a capillary gap between the metals being joined. Many forms of brazing alloys are used for fulfilling this requirement. Brazing rods are perhaps the most popular forms of brazing alloys used world over by professionals.

What is a Brazing Rod?

Brazing rod is a piece of metal in the shape of a rod. It melts during the brazing process and attaches to the separate pieces of metals in order to join them together once cooled.

What are the Metals Used for Making Brazing Rods?

Brazing process has the ability to join different metals and components of dissimilar size and mass. However, for this, the perfect form of brazing alloy (filler metal which melts above 450˚C but below the temperatures at which metals being joined melt) has to be present. Therefore, brazing rods have to be made from different metals like aluminum, silver, steel, bronze etc.

What is Flux Coated Brazing Rod?

There are many types of brazing processes which are conducted in different atmospheres. In the one which is not contained within an inert or reducing atmosphere environment (for example a furnace,) flux is needed to prevent oxides from forming when the metal is heated. Not only this, flux also cleans up any contamination that is left on the brazing surfaces. Flux too comes in various forms like flux paste, liquid, powder or pre-made brazing pastes that combine flux with filler metal powder. Sometimes, flux is applied to brazing rods either in the form of a coating of flux or a flux core. This flux flows into the joint when the brazing rod is applied to the heated joint and is displaced by the molten filler metal entering the joint.

To know more about brazing rods as well as other forms of brazing alloys, read Brazing Rod

Video Rating: 5 / 5

• Comfortable, user friendly economy goggles
• Sturdily built and easy-to-adjust
• Includes a #5 lens
• Providing adequate protection for gas welding
• Most often used for short-run, small job, gas welding applications

Product Description
Comfortable, easy to use, with #5 shaded lens for adequate protection when gas welding. Most often used for short-run, small jobs.

US Forge 108 Shaded #5 Economy Cup Brazing Goggles