When brazing, several precautions must be taken to ensure the process is successful and the final product is of high quality. These precautions include proper cleaning, careful control of the furnace cycle, and appropriate brazing techniques.
Proper Cleaning: Before brazing, it is crucial to clean the parts thoroughly to remove all oxides, contaminants, and oils. This step is essential because any residue can interfere with the brazing process, leading to poor joint quality or failure. Cleaning ensures that the braze alloy can flow properly and adhere to the base material without any hindrances.
Careful Control of the Furnace Cycle: The furnace cycle plays a significant role in the success of the brazing operation. Parts should not be ramped too quickly to avoid distortion and uneven temperature distribution. Proper stabilization of the parts is necessary to ensure proper braze flow. Rapid quenching should be avoided as it can lead to distortion, quench cracking of the braze joint, and splatter. The temperature and vacuum levels during brazing, especially for high-temperature nickel alloys, should be precisely controlled, typically performed at 1040-1200°C in a vacuum level of 10-4 to 10-5 mbar.
Appropriate Brazing Techniques: For stainless steel, stricter cleaning is required to remove any grease and oil film, and brazing should be carried out immediately after cleaning. The choice of heating method (flame, induction, or furnace) and the furnace's temperature control system are critical. When using hydrogen as a protective gas, the requirements depend on the brazing temperature and the base material's composition. Cooling should be done naturally in air to prevent brittleness and cracking.
Atmosphere Control: Brazing requires an atmosphere devoid of oxidants, especially oxygen and water. This is crucial to prevent the reformation of oxide layers and corrosive reactions. The atmosphere should ideally be neutral, with conditions such as oxygen content less than 100 ppm and humidity below -40°C. This ensures that the brazing process can proceed without the formation of unwanted compounds that could compromise the integrity of the brazed assembly.
By adhering to these precautions, the risks of common problems like splatter, quench cracking, and distortion can be significantly reduced, leading to a successful brazing operation.
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