The key to successful pin brazing, as with traditional brazing techniques, is based on many key factors and there are several main factors, but when it comes to pin brazing, there are only five areas where which I focus primarily on when I teach training classes or presentations. These are the power supply, the preparation of the surface for connection, the preparation of the surface for your ground device, having the correct adjustment settings, and finally the competence of the operator. The above factors can often be overlooked individually, often leading to inadequate results and costly delays, so it is important that both operators and businesses ensure that they have received or provided training and certification from an Instructor. qualified and experienced.
In not wanting to turn this article into an ‘instruction manual’, it is my intention to focus in more detail on why some of the above factors are imperative considerations in the design and development of the Pin Brazing product and the consideration that must be taken into account when assume the responsibility. to develop and pioneer these innovative processes.
Connection design.
Welded joints using silver-based filler metals must always have a capillary space into which molten filler metal can flow. Joint strength will vary with joint spacing and degree of overlap between connection type and base metal; Joint gaps of 0.03 to 0.08 mm (0.0012 to 0.0031 in) are recommended for best capillary action and joint strength. During the pin brazing process, the brazing material is drawn into the joint, which is caused by the attraction between the molecules of the brazing material and the molecules on the metal surface to be joined. This will only work if: The metal surface is clean, the clearance between the metal surfaces is correct, and the metal in the joint area is hot enough to allow the pin braze to flow evenly. Connection methods, such as crimp terminals, must be precision fabricated to ensure optimal capillary space for joint strength and integrity, while allowing excess heat created during the start of the brazing arc to flow freely from the substrate material to reduce or increase unnecessary damage. Heat affected zone (HAZ).
Brazing pins and their respective alloys should be selected based on their suitability for a particular application. Consideration should be given to the substrate design, base metal, brazing process, and ergonomics of operation. The use of free-flowing, high-silver, cadmium-free filler alloys with low melting ranges is essential in the development of brazing pins, which help protect the parent material during the arc process and allow a greater flow maximizing the 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, it must have a suitable service life at the temperature, and it must be suitable for both the heating method (in the case of pin brazing, the arc temperature can be above 2000 degrees Celsius) and base metals and become active below the melting point of the brazing alloy. It must remain active during the entire welding cycle, eliminating the oxides formed in the base metal. Observations should be made if the flux residues appear blackened and glassy, as the flux has probably been used up during heating. This could be the result of contaminated flux (from very old or improperly stored solder pins) or more likely the components have overheated, possibly due to improper setting on the solder gun or a discharged battery.
Pre-cleaning.
To promote a good bond, the connecting substrate must be free of grease and any surface rust before welding. Grease and oil are best removed with a degreasing solvent. Prior to this, pin brazing aids can be used, which will often include surface preparation equipment such as die grinders and angle grinders equipped with carbide burs, mounted tips, or abrasive flap discs. These mechanical surface preparation devices are designed to be used sparingly so as not to cause interruptions in substrate thickness or create uneven pits or channels that may interfere with capillary action or arc length. Rust on the surface can also be removed with a medium grade abrasive cloth. The quality of the consumables must also be considered, as with the substrate material, components that have been exposed to moisture or grease can be the cause of poor welding results. Care must be taken at all times to ensure that consumables remain sealed in their original containers until required for use and must be inspected for surface oxidation or grease before use.
Battery status.
Most standard pin brazing systems are powered by a 36-42 volt battery pack or a welding generator configured to reflect the characteristics of the battery pack. Careful consideration and testing has been done 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 used. Therefore only pre-approved batteries should be used, these battery types or their details can only be obtained from your pin brazing supplier or equipment manufacturer and it is important to note that different brazing equipment manufacturers use different types of batteries, which are adapted for use only with their respective tools and consumables. As a user, batteries must be cared for according to their user manual, and even with heavy use they can last for many years.
Electrobraze pin brazing equipment and consumables have been developed through experience for use in extreme environments and remote locations around the world through extensive field experience and troubleshooting in the petroleum industries, gas, railways and utilities. In addition, all the equipment has been developed for the comfort of the operator in the field, being both light and practical. Using electromechanical technology for a safer, more practical, resistant and reliable system. This ensures that operators working in the field can be safe and have full control over their equipment and maintenance. You can find product information and more information on pin brazing and the pin brazing process at http://www.electrobraze.com/about.html
