When brazing, it is important to wear appropriate personal protective equipment (PPE) to protect against potential hazards. The recommended PPE includes eye protection (safety glasses with side shields or welders goggles), face protection (welders helmet), hand/arm protection (leather gloves and gauntlets), head protection (welders helmet), and body protection (leather apron). These PPE items are necessary to protect against sparks, heat, and potential splatter of the braze alloy.
In addition to wearing PPE, there are other factors to consider when brazing. It is recommended to avoid using screws or bolts as they can sinter together at high temperatures and become difficult to remove. If springs or clamps are needed, they should be able to withstand the temperatures encountered during brazing. Metallic fixtures used should have all points of contact with the brazed assembly masked with stop-off paints to prevent unwanted braze flow. The fixtures should also be cleaned and vacuum baked before use to remove any sources of contamination.
The development of a brazing cycle is influenced by factors such as the composition of the base metal and braze alloy, the mass of the assembly, and the joint design. Proper cleaning of the part is critical before the brazing process to ensure it is free of oxides, contaminants, and oils. The furnace cycle is equally important, and parts should be ramped up to temperature at an appropriate rate to prevent distortion and uneven temperature throughout the assembly. Quenching too rapidly after brazing can also cause distortion, quench cracking, and splatter.
For brazing high-temperature nickel alloys, the brazing is typically performed at temperatures between 1040-1200°C (1900-2200°F) in a vacuum level of 10-4 to 10-5 mbar (10-4 to 10-5 Torr). The brazing temperature is usually 40-65°C (100-150°F) above the melting point of the braze alloy.
The success of the brazing operation also relies on joint design. A properly designed joint should have an unbroken capillary path with gaps not exceeding 0.1mm. Self-supporting or self-jigging joints are preferred to avoid the need for expensive furnace jigs that may move during the process and occupy furnace space.
It is important to ensure that components to be brazed are clean, free from swarf, rust, and excess grease before brazing. This will help ensure proper bonding and quality of the brazed joint.
Overall, by wearing the appropriate PPE, considering factors such as joint design and cleanliness, and following proper brazing techniques, common problems such as splatter of the braze alloy, quench cracking, and distortion can be prevented, leading to successful brazing operations.
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