Joining Technologies

-
Welding and soldering processes

Univ.-Prof. Dr.-Ing. Prof. h.c. Stefan Böhm

Fachgebiet Trennende und Fügende Fertigungsverfahren (tff)
Universität Kassel
Kurt-Wolters-Str. 3
34125 Kassel
Tel.: +49 561-804-3141
Fax: +49 561-804-2045
s.boehm@uni-kassel.de
http://www.tff-kassel.de
Agenda

 Introduction

 Welding processes and welding equipment

 Materials and their weldability

 Manufacturing and Testing

 Soldering processes

Joining Technologies
Welding and soldering processes
Practical examples

Oldest known picture of soldering,

1475 b.c.
Egyptian gold smith
(blow pipe and wood coal fire)

Brazing of bicycle frame, ca. 1890

3
Quelle: Bernsdorf, Auf heißen Spuren

Joining Technologies
Welding and soldering processes
Practical examples 2

Rock arm of Daimler-Benz

engine, ceramic plate for wear
protection

Hart metal on a side milling cutter

Reflowelding of smd
4
Quelle: Lugscheider, Fügen von Hochleistungswerkstoffen SMD-Technik Buch

Joining Technologies
Welding and soldering processes
Practical example 3

Laser beam brazing for seeable body in

white parts

Quelle: Audi

Soldering in electronic industries for

different electrical parts
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Joining Technologies
Welding and soldering processes
Definition of soldering
 soldering:  soldering:

• Liquid phase by melting of a solder • Melt temperature of the solder is

(fusion soldering) OR lower than the melt temperature of
the base metal
• Liquid phase by diffusion from the
boundary layer (diffusion soldering) • Base material is wetted, not melted

• Mostly used with fluxes, to enable

wetting and/or with shielding gas

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Welding and soldering processes
Definition of soldering
 Joint formation by
● Wetting of the solid surfaces of the
joint
● With liquid solder

● Solidifying solder alloys with the

base material

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Welding and soldering processes
Physical principal and influencing factors

Solid specimen surfaces Liquid solder •diffusion

•alloying
•cooling

temperature Brazing fit

Soldering
process

wetting flux
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Welding and soldering processes
Wetting

q = 180° q = 30° q = 0°
No wetting Sound wetting Ideal wetting
EO >> E A EO < E A E O << E A
EA : adhesion energy E O : surface energy q : wetting angle
Quelle: iwb

 Wetting means a specific reaction of the liquid solder with the solid surface
 The droplet is affected by cohesive force and adhesive force
 Wetting is measured by the surface tension
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Welding and soldering processes
Wetting process

gl
q
gs
g ls
Youngs equitation: gs =g l  cosq +gLS
Mit gs : surface energy of the solid phase [N/m]
gl : surface energy of the liquid phase [N/m]
g ls : surface energy of the boundary layer solid-liquid [N/m]
q : contact angle
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Quelle: iwb

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Welding and soldering processes
Tasks and effects of the flux

 Dissolution of the adsorption layer (gas, water)

 Remove oxides, sulfides and other reaction products
 Dissolving of specimen substrate molecules and start of the intermetallic joint
building
 Protection for oxidization
 Assistance of the wetting

Quelle: iwb
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Welding and soldering processes
 flux

solvent solid

Additives:
basis: Activator foam regulation
Colophony thickener (solder paste)
Synthetic resin anti setting agent
diluent

Halogenated: e.g. Non-halogene: e..g carboxylic

Aminhydrochloride acid

Quelle: iwb 12

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Welding and soldering processes
Capillary effect
 Differentiation by solder joint  fusion brazing
● fusion brazing depending on  depending on capillary action of the
capillary action (gap soldering) solder

– Distance of solder gap < 0,25 mm  Capillary pressure pk = 2gh/b

– gh: bond stress between solder and
● braze welding
solid
– Distance of solder gap < 0,5 mm
– b: gap size
– Joint shape also V- and X-shape
 Narrow gap is good for capillary
filling
 Too narrow gap enlarges the
danger of flux inclusions and bad
tensile properties

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Welding and soldering processes
Brazing fit and capillary action

right wrong

0,05...0,2

>0,5
Melting solder Melting solder

Flowed solder Melted solder

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Quelle: iwb

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Welding and soldering processes
Brazing fit and capillary action,
rules for gap soldering
 Rules fusion brazing depending on capillary
Solder penetrates both gaps
action:
Inlay solder Applied solder

● Brazing fits needs to be in flux direction

● Knurling groofe in flux direction helps to

defect center the parts

 Inlay solder:

● needs to be put in place at the biggest

gap width, to have capillary pressure
Knurling here into the narrowing gaps

● Is sucked into narrowing gaps and

enables a checking for complete wetting
and bonding

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Welding and soldering processes
 20
mm  For gap soldering
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● Choose a small gap size
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Capillary head

12 gap soldering ● Not too narrow to avoid flux

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8 Weld brazing
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 Weld brazing
4
2 ● Similar to gas welding
0 0,05 0,1 0,2 0,3 0,4 mm 0,5 ● High solder consumption
Gap width
righ too large

too narrow Still acceptable for

manual soldering
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Welding and soldering processes
Tin lead phase diagram

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Welding and soldering processes
 Temperature curve for soldering

Soldering temperature

 Working temperature
temperature

Soak temperature
● Lowest surface temperature of the
specimen at which
– wetting takes place

– Solder flows

– Solder alloys with the base material

Soak time
Heating time Hold time Cooling time

Soldering time
Total time Zeit

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Welding and soldering processes
Classification of soldering processes

soldering
brazing
(high temperature brazing)
Working
temperatur
Applied solder
Soldering Insert solder
Solder
and brazing
feeding Dip soldering
processes and brazing

Energy carrier for solid

heating gas
liquid
radiation
Electrical current 19
Quelle: iwb

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Welding and soldering processes
Classification by working temperature
Soldering brazing High temperature brazing
Working temperature <450°C >450°C >900°C
flux + + -
vacuum - + +
Quelle: iwb Shielding gas - + +

 soldering:
● Low tensile strength, leakproof, electric conductable
● Solder is based on tin and lead
● Low heat input for heat-sensitive parts, e.g. elektronics

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Joining Technologies
Welding and soldering processes
Classification by working temperature
Soldering brazing High temperature brazing
Working temperature <450°C >450°C >900°C
flux + + -
vacuum - + +
Quelle: iwb Shielding gas - + +

 brazing:
● Tensile strength as high as base material
● Solder is based on cupper alloys with silver
● Furnace brazing without flux, especially for light weight metals

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Joining Technologies
Welding and soldering processes
Examples, metallographic examination

Cupper solder
Diffusion layer
Electro galvanised sheet

(400:1,
etching Nitral 2%)

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Quelle: ESAB GmbH

Joining Technologies
Welding and soldering processes
Classification by working temperature
Soldering brazing High temperature brazing
Working temperature <450°C >450°C >900°C
flux + + -
vacuum - + +
Quelle: iwb Shielding gas - + +

 High temperature brazing:

● Tensile strength as high as base material
● For steel, Ni- and Co-Alloys
● Solder based on Ag-, Au-, Co-, Cu- or Ni-basis

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Welding and soldering processes
Classification by solder application

Application by inserted solder Application by applied solder

Flus and solder Burning gas mixture
specimen
solder
burner

flame
seam
Brazing fit

specimen
flame
Application by dipping
Passage angle card
=7°

Drying way

Soldering bath Flux bath

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Quelle: iwb With application mandrel With application madrel

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Welding and soldering processes
Energy carrier for heating: solid (soldering gun)

tubular solder with flux core Soldering gun

Application in
electronic workshops

wire

Turbular solder with flux

e.g.. soldering lug

wire

Soldering gun

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Quelle: iwb

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Welding and soldering processes
Energy carrier for heating: solid (rolling)

counterroller

Application in
electronic workshops
Flat part
(e.g. electronics))

Solder roller
Cover salt

Solder bath
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Quelle: iwb

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Welding and soldering processes
Energy carrier for heating: gas (inserted solder)

Flux and solder specimen

flame

Application:
Bicycle frame

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Quelle: iwb

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Welding and soldering processes
Energy carrier for heating: gas (applied solder)

Gas mixture

solder burner

Lötnaht
Brazing fit
specimen

e.g.:
Wide flame
Quelle: iwb
installation function 28

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Welding and soldering processes
Energy carrier for heating: gas (braze welding)

solder Acytelene and oxygene

burner
seam

hardFlame
Joint fitting

Application example:
Cooling fins for heat
specimen exchanger 29
Quelle: iwb

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Welding and soldering processes
Energy carrier for heating: gas (mechanized gap soldering)

Application example:
tube bundle heat exchanger solder

Burning gas
mixture

Field burner 30
Quelle: iwb specimen

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Welding and soldering processes
Energy carrier for heating: liquid – drag soldering

Scraper holder card

Solder bath
Flux bath

Application example:
electronic workshops

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Quelle: Peter Jordan GmbH

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Welding and soldering processes
Energy carrier for heating: liquid – wave soldering

Passage angle card

=7°

Drying line

Solder with solder wave Flux bath

Fluxer with foam wave
Application example:
electronic workshops

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Quelle: Peter Jordan GmbH

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Welding and soldering processes
Energy carrier for heating: liquid – ultrasonic soldering

US-oscillator specimen

Sonotrode

Platform with
Cooler blower

Solder bath

socket

Application example:
special process (oxid layer remove by ultrasonic)
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Quelle: Peter Jordan GmbH

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Welding and soldering processes
Energy carrier for heating: radiation – laser beam brazing

Current source

Eliptic mirror

Solid state oder 1 mm

gas laser
Quelle: mta automation ag Quelle: Siemens
Light radiation

Laser beam

lense

Light source Shielding gas

specimen
Braze seam Quelle: Audi

application:
Turning table electronic industries
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Quelle: iwb car industries
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Welding and soldering processes
Energy carrier for heating: radiation – electron beam
brazing

Vaccum chamber
cathode
Current source
anode

Electrical focus lense

Deflection system
Electron beam
Working chamber
Brazing seam

Application:
Special application
specimen 35
Quelle: iwb Turning unit

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Welding and soldering processes
Energy carrier for heating: current – induction brazing

specimen

generator
Solder seam

Induction
coil

36
Quelle: iwb

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Welding and soldering processes
Energy carrier for heating: electric current – resistance
soldering
indirect direct

electrode
(carrier)
specimen specimen
(e.g. Hard metal) Solder, fluxl Formed

Current source
electrode tip
(coal)
Solder, flux

Electrode
Current source tip
specimen (coal, thungsten)
Copper electrode
(e.g. steel)
Second
electrode
(carrier) 37
Quelle: iwb

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Welding and soldering processes
Energy carrier for heating: electric current – arc soldering

Electrode holder
Coal electrode
Hard solder
(e.g.: phosphoric)

Current source
Lötnaht arc
Brazing fit

specimen 38

Joining Technologies
Welding and soldering processes
Energy carrier for heating: electric current – MSG
soldering
 Solder is applied by filler wire which melt temperature is below of the base
material melt temperature
 Electric arc is for heating electrode and base material to working temperature
 High solder speed, no flux is deeded
 Use in body in white production: for zink coated steel
● Less zink burn out than for welding, corrosion resistance remains, porefree
● Solder material bronze

MIG-Hard brazing of steel with impulse arc, filler material penetration< 0,5xsheet thickness 39

Joining Technologies
Welding and soldering processes
Energy carrier for heating: electric current – MSG
soldering
 Advantages for MSG-soldering:  Disadvantages
● Low heat input ● Expensive filler wire
● Good gap bridgeability ● Flat seam only with impulse arc
● Good suitability for Zn- and Al-
coated sheets
● Remain of corrosion resistance
● High brazing speed compared to
other brazing processes
● No flux needed
● Not weld penetration at seam
edges

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Welding and soldering processes
Energy carrier for heating: electric current – MSG brazing

Burner and nozzle

For MSG-soldering
MSG brazing wis impulsed arc at zinc
source: Böhler Thyssen coated steel (1mm and 2mm thickness)
Welding Micrograph of a Mig-brazing seam
source: Merkle Schweißanlagen- source Baum/Fichter Der
Technik Schutzgasschweißer 41

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Welding and soldering processes
Comparison of different brazing processes
Laser oven Gas flame Current
Energy source: induction
(Resistanc)
Machine costs
portability
Energy density
Soldering time
flexibility
Process factors
handling
quality

Braze ability of large parts

Sheet part
Massive part

Profitability of small / big massive parts

Job shop
Mass production

Profitability of small / big massive parts

Job shop
Mass production

Very high high medium Low Very low

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Joining Technologies
Welding and soldering processes
Design and process steps for brazing and soldering
T-Joint
Scarf joint
Constructive design of the brazing fit
Butt joint
Joint materials
Lap joint
brazeability Solder materials
flux

Pre- and post treatment of brazing seam

Strength of solded seams

Testing of solded seams

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Joining Technologies
Welding and soldering processes
Design and process steps for brazing and soldering
 Design of the brazing fit  Common joint geometries
● Normally parallel for a constant gap ● T-joint
thickness
● Butt-joint
● Keep maximum and minimum
● Lap-joint
width
● Scarf-joint
● Brazing fit shall not grow in solder
flux direction (avoid capillary flow
break)
● Maximum brazing fit length 15 mm
(to have sufficient capillary
pressure)
● Tool marks in solder flow direction

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Joining Technologies
Welding and soldering processes
Design and process steps for brazing and soldering

Scarf joint

T-joint

Lap joint

Butt joint 45

Joining Technologies
Welding and soldering processes
Design and process steps for brazing and soldering
 Braze ability is given if:  Advantages
● Suitable solder and flux for the ● Due to low heat input braze ability
base material is given is less limited than weldablity
● Base material has no disadvantage ● Not weld able metals are braze
material transformation at brazing able – if the base metals are braze
temperature able with the solder (alloying)
● Melting temperature of solder is
below melting temperature of base
material
● Solder and base material alloy in a
mixed crystal

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Joining Technologies
Welding and soldering processes
Design and process steps for brazing and soldering
 Solder brittleness
● Inter crystalline crack initiation
● Liquid solder penetrates along the
grain boundaries into base material
● Crack of grain boundaries
● Steel- and Cu- rich solders have
low solder brittleness
● Hard brazing seldom has solder
brittleness

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Joining Technologies
Welding and soldering processes
Design and process steps for brazing and soldering
 Pre- and post treatment of solder ● Effectively the layer is limited to
joints 0,5mm

● Mechanical and chemical cleaning ● Melting temperature of flux needs

of joints geometries is needed to be less than solder melting
temperature
● Activation of the surfaces
● Mechanical or chemical cleaning
● Sufficient surface structure for after the process is needed due to
machined specimen the corrosive effect of flux
● Surface coatings and oxide layers – Mechnical: brushing, blasting
needs to be removed
– Chemical: pickling with dilute acid
● Flux application
– washing with hot or cold water
● Release and bonding of the oxide
 Flux is main disadvantage for
layers due to reduction
soldering
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Joining Technologies
Welding and soldering processes
Design and process steps for brazing and soldering

 Strength of solder connection  Impact factors on strength

● Brazing is increasingly used for ● Strength of solder
structural joints
● Size of brazing fit
● Important is a brazing suitable
● Surface and circumference of the
design
solder joint
● Working temperature
● Filling degree
● Effect of flux

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Joining Technologies
Welding and soldering processes
Design and process steps for brazing and soldering
 Strength of solder connection
 Impact factor area
● Strength decreases with increasing
surface area
– Huge soldering areas increases
defects, like pores, gas- and flux
inclusions, and unheated areas
● Decrease of strength due to bigger
areas mostly is bigger than the
strength increase by bigger areas
Joining Technologies
Welding and soldering processes
 Strength of solder connection
 Impact factor solder
● Based on strength of the solder
● Tensile strength of the joint
increases with tensile strength of
the solder
● Strength of joint can be higher than
the strength of the solder due to
– Alloying
– Forming constraint: due to the base
material forming constraint and the
joint geometries the state of stress
is multi dimesional
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Design and process steps for brazing and soldering
 Strength of brazing joints
 Impact factor flux
● Erase existing or forming oxide
layers on base material and solder
● Increase surface tension of joint
partners
● Sufficient supply of flux needs to be
secured for solder and base
material
● Activation temperature of flux
needs to be at least 50 – 100 °C
below working temperature of
solder
 Strength of brazing joints
 Impact factor temperature and
filling grad
● Maintain right brazing temperature
is important
● To low temperature: no or not
sufficient diffusion and alloying of
solder and base material
● To high temperature: risk of
evaporation of alloying elements of
the solder (solder over heating)
● Insufficient filled brazing fits reduce
the tensile strength
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Joining Technologies
Welding and soldering processes
Advantages of soldering and brazing

 Combination of different materials (especially metals)

 Low heat input
 Low distortion at soldering and brazing
 Good electric conductivity
 Joining of parts with different thicknesses
 Easily automatable

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Joining Technologies
Welding and soldering processes
Disadvantages of soldering and brazing

 Soldering has a low strength

 Pretreatment of specimen needs to be done with care
 Strength decrease at high temperatures
 Risk of corrosion at solder joints
 Flux inclusions
 Intensive post treatment of joint areas necessary

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Joining Technologies
Welding and soldering processes
What did you learn?

 Definition of soldering and brazing

 Wettig by solder
 Tasks and effects of flux
 Brazing gap and capillary action
 Clasification of soldering and brazing processes
 Heat sources for soldering and brazing
 Design and process steps for soldering
 Advantages and disadvanteges of soldering and brazing

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Joining Technologies
Welding and soldering processes
Vielen Dank für Ihre Aufmerksamkeit!

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Joining Technologies
Welding and soldering processes