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Soldering
A method of joining metal parts using an alloy of
low melting point (solder) below 450 C (800 F).
Heat is applied to the metal parts, and the alloy
metal is pressed against the joint, melts, and is
drawn into the joint by capillary action and
around the materials to be joined by '
wetting action'.
After the metal cools, the resulting joints are
not as strong as the base metal, but have
adequate strength, electrical conductivity, and
water-tightness for many uses.
One application of
soldering is making
connections between
electronic parts and
printed circuit boards.
Another is in plumbing.
Joints in sheet-metal
objects such as cans
for food, roof flashing,
and drain gutters were
also traditionally
soldered.
Jewelry and small
mechanical parts are
often assembled by
soldering.
Soldering can
also be used as a
repair technique
to patch a leak in
a container or
cooking vessel.
No wetting
Excessive wetting
Flux entrapment
Lack of fill (voids, porosity)
Unsatisfactory surface appearance
Base metal erosion
Pipe/Mechanical soldering
Soldering defects
Soldering defects are solder joints that are not soldered correctly.
These defects may arise when solder temperature is too low.
When the base metals are too cold, the solder will not flow and will
"ball up", without creating the metallurgial bond.
An incorrect solder type (for example, electronics solder for
mechanical joints or vice versa) will lead to a weak joint.
An incorrect or missing flux can corrode the metals in the joint.
Without flux the joint may not be clean.
A dirty or contaminated joint leads to a weak bond. A lack of solder on
a joint will make the joint fail.
An excess of solder can create a "solder bridge" which is a short
circuit. Movement of metals being soldered before the solder has cooled
will make the solder appear grainy and may cause a weakened joint.
Soldering defects in electronics can lead to short circuits, high
resistance in the joint, intermittent connections, components
overheating, and damaged circuit boards. Flux left around integrated
circuits' leads will lead to inter-lead leakage.
It is a big issue on surface mount components and causes improper
device operation as moisture absorption rises. In mechanical joints
defects lead to joint failure and corrosion
Soldering processes
Wave soldering
Reflow soldering
Infrared soldering
Induction soldering
Ultrasonic soldering
Dip soldering
Furnace soldering
Iron soldering
Resistance soldering
Torch soldering
Silver soldering/Brazing
Brazing
Is similar to soldering but uses higher melting
temperature alloys, based on copper, as the filler metal.
"Hard soldering", or "silver soldering" (performed with
high-temperature solder containing up to 40% silver) is
also a form of brazing, and involves solders with melting
points above 450 C. Even though the term "silver
soldering" is more often used than silver brazing, it is
technically incorrect.
Since lead used in traditional solder alloys is toxic, much
effort in industry has been directed to adapting soldering
techniques to use lead-free alloys for assembly of
electronic devices and for potable water supply piping.
Brazing
Brazing is a joining process whereby a non-ferrous filler
metal and an alloy are heated to melting temperature
(above 450C;) and distributed between two or more
close-fitting parts by capillary action.
At its liquid temperature, the molten filler metal interacts
with a thin layer of the base metal, cooling to form an
exceptionally strong, sealed joint due to grain structure
interaction. T
he brazed joint becomes a sandwich of different layers,
each metallurgically linked to each other.
Common brazements are about 1/3 as strong as the
materials they join, because the metals partially dissolve
each other at the interface, and usually the grain
structure and joint alloy is uncontrolled.
To create high-strength brazes, sometimes a brazement
can be annealed, or cooled at a controlled rate, so that
the joint's grain structure and alloying is controlled.
one that offers extremely clean, superior, flux free braze joints while
providing high integrity and strength.
The process can be expensive because it is performed inside a
vacuum chamber vessel however, the advantages are significant.
For example, furnace operating temperatures, when using
specialized vacuum vessels, can reach temperatures of 2400 C.
Other high temperature vacuum furnaces are available ranging from
1500 C and up at a much lesser cost.
Temperature uniformity is maintained on the work piece when
heating in a vacuum, greatly reducing residual stresses because of
slow heating and cooling cycles.
This, in turn, can have a significant impact on the thermal and
mechanical properties of the material, thus providing unique heat
treatment capabilities.
One such capability is heat treating or age hardening the work piece
while performing a metal-joining process, all in a single furnace
thermal cycle.
Possible problems
A brazing operation may cause defects in the
base metal, especially if it is in stress. This can
be due either to the material not being properly
annealed before brazing, or to thermal expansion
stress during heating.
An example of this is the silver brazing of coppernickel alloys, where even moderate stress in the
base material causes intergranular penetration by
molten filler material during brazing, resulting in
cracking at the joint.
Any flux residues left after brazing must be
thoroughly removed; otherwise, severe corrosion
may eventually occur.
Brazing processes
Block Brazing
Diffusion Brazing
Dip Brazing
Exothermic Brazing
Flow Brazing
Furnace Brazing
Induction Brazing
Infrared Brazing
Resistance Brazing
Torch Brazing
Twin Carbon Arc Brazing
Vacuum Brazing
Riveting
Howrah bridge, links the city of Howrah to its twin city, Kolkata (Calcutta). On 14
June 1965 it was renamed Rabindra Setu, after Rabindranath Tagore the first
Indian Nobel laureate. However it is still popularly known as the Howrah
Bridge.
The bridge is 705 metres long and 30 metres wide. More than 26,500 MT of
high-tensile steel went into this unique bridge supported by two piers, each
nearly 90 meters above the road. An engineering marvel, it expands as much
as a metre during a summer day. This is constructed entirely by riveting,
without nuts or bolts
Riveted Truss over Orange River. This river is the longest river in South
Africa. It rises in the Drakensberg mountains in Lesotho, flowing
westwards through South Africa to the Atlantic Ocean. The river forms part
of the international borders between South Africa and Namibia and
between South Africa and Lesotho, as well as several provincial borders
within South Africa.