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Successful Pin Brazing

By Glenn Symington

The key to successful Pin Brazing as with traditional Brazing techniques relies upon many key factors and there

are several main factors, but when it comes to Pin Brazing there are just five areas on which I primarily focus

when providing training classes or presentations. These are Power Supply, Surface Preparation for your

connection, Surface Preparation for your Earth Device, having the correct Adjustment Setup and finallyOperator Proficiency. The above factors can often be overlooked individually, often creating inadequate

results and expensive delays so it is important that both operators and companies ensure that they have either

received or made provision for training and certification by qualified, experienced Instructors.

Not wanting to make this article into an instruction manual it is my intention as Managing Director and

Founder of my own Pin Brazing Company to focus on in more detail why some of the above factors are

imperative considerations in both Pin Brazing product design and development and the consideration that

must be given when taking the responsibility to develop and pioneer these innovative processes in the way

that we do.

Connection Design.

Brazed joints using Silver based Filler metals should always have a capillary gap into which the molten filler

metal can flow. Joint strength will vary with the joint gap and the degree of overlap between Connection type

and parent metal, joint clearances of 0.03 to 0.08 mm (0.0012 to 0.0031 in) are recommended for the best

capillary action and joint strength. During the Pin Brazing process, brazing material is drawn into the joint

which is caused by the attraction between the molecules of the brazing material and the molecules of the

metal surface to be joined. This will only work if: The surface of the metal is clean, the clearance between the

metal surfaces is correct and the metal at the joint area is hot enough to allow the Pin Brazing material to

evenly flow. Connection methods such as Crimp Terminals should be precision manufactured to ensure

optimum capillary gap for joint strength and integrity, whilst also allowing excess heat created during initiation

of the Pin Brazing Arc to flow freely away from the Substrate material in order reducing and unnecessary

damage or increased Heat Affected Zone (HAZ).

Brazing Pins and their respective Alloys should be selected on their suitability for a particular application.

Consideration should be given to the substrate design, the parent metal, the brazing process and the

economics of the job. The use of Cadmium free, high Silver, free flowing filler Alloys with low melting ranges

are essential, which must aid in the shielding of the Parent material during the Arc process and allow for an

increased flow maximizing in available surface area, which in turn allows for a more substantial electrical and

mechanical connection.

In the Manufacture of Brazing Pins the choice of flux is as important as the choice of filler metal. The working

range of the flux must be compatible with the brazing temperature, must have suitable life at temperature and

should be suitable for both the heating method (in the case of Pin Brazing, Arc temperature could be in excess

of 2000 C) and the parent metals and become active below the melting point of the brazing alloy. It must stay

active right through the brazing cycle removing any oxides formed on the parent metal. Observations shouldbe made if the flux residues appear blackened and glassy as the flux has probably been exhausted during

heating. This could be the result of contaminated flux (from very old or incorrectly stored Brazing Pins) or more

likely the components have been overheated, possibly due to an incorrect adjustment setting on the Brazing

Gun or an un-charged Battery Pack.

Pre-cleaning.

To promote good bonding the connection substrate should be free from grease and any surface oxide prior to

brazing. Grease and oil are best removed using a degreasing solvent. Prior to this Pin Brazing Ancillaries can be

used which will often include Surface Preparation Equipment such as Die Grinders and Angle Grinders fitted

with Carbide Burrs, Mounted Points or abrasive Flap Discs. These mechanical surface preparation devices are

intended to be utilized sparingly in order to not cause disruption to the substrate thickness or create unevenpits or troughs which may interfere with Capillary action or Arc length. Surface oxide can also be removed with

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Successful Pin Brazing

By Glenn Symington

a medium grade abrasive cloth. Consideration should also to be given to Consumable quality, as with Substrate

material, components which have been exposed to moisture or grease can be the cause of defective brazes

results. Care should be taken at all times to ensure that Consumables remain sealed in their original containers

until required for use and should be inspected for surface oxidization or grease prior to being used.

Battery Status.

Most standard Pin Brazing Systems operate using a 36-42volt Battery Pack or Welding Generator set up to

mirror the characteristics of the Battery pack. Careful consideration and testing has gone in to find batteries

that are suitable for the extreme operational demands of the Pin Brazing Process and the equally extreme

environments in which the process is utilised. Therefore only pre-approved batteries must be used, these

battery types or their details will only be obtainable from your Pin Brazing Supplier or equipment

manufacturer and it is important to note that different Pin Brazing Equipment Manufacturers do utilise

different Battery types, which are attuned for use with only their respective tools and consumables. As a user

batteries must be cared for in accordance with your user manual, and even under heavy usage could last for

many years.

Electrobraze Pin Brazing Equipment and Consumables have been developed through experience for use in

extreme environments and remote locations worldwide through extensive field and trouble-shooting

experience in the Oil, Gas, Rail and Utilities industries. Whats more all pieces of equipment have been

developed for In-field operator convenience being both lightweight and practical. Using electromechanical

technology for a safer, more practical, rugged and reliable system. Which, ensures that operators working in

the field can be safe and have full control over their equipment and maintenance.

For further product Information please visit our Website athttp://www.electrobraze.com/.Alternatively for

further reading on Pin Brazing and the Pin Brazing Process please visit http://ezinearticles.com/?Pin-

Brazing&id=6451470

http://www.electrobraze.com/http://www.electrobraze.com/http://www.electrobraze.com/http://ezinearticles.com/?Pin-Brazing&id=6451470http://ezinearticles.com/?Pin-Brazing&id=6451470http://ezinearticles.com/?Pin-Brazing&id=6451470http://ezinearticles.com/?Pin-Brazing&id=6451470http://ezinearticles.com/?Pin-Brazing&id=6451470http://www.electrobraze.com/