In the world of brazing, selecting the coated alloy with the right amount of flux for the base materials to be brazed is crucial for achieving high-quality results.
Over time, the use of alloys coated with flux has significantly increased, thanks to the growing quality of available products and their convenience and consistency in providing the correct flux-to-metal ratio, overcoming the challenges posed by the traditional use of separate paste or powder.
Traditional flux powder is less precise regarding consistency and repeatability, affected by powder granularity and moisture variables. Moreover, the powder can become volatile when exposed to flame, contaminating the work area. On the other hand, flux paste, often diluted with distilled water, presents homogeneity issues, with the variable addition of water by operators and the risk of drying out, making the process less manageable.
The transition to coated alloys offers a solution to these problems, allowing greater control over the amount of flux applied.
Innovations and Environmental Considerations
Recent innovations in the brazing field have introduced alloys with improved characteristics, such as increased corrosion resistance and better flow properties, extending the lifespan of brazed components.
Furthermore, a growing focus on environmental and ecological issues is driving the production of more sustainable alloys, reducing environmental impact and improving workplace safety.
Selection of the Alloy and Specific Applications
Selecting the suitable coated alloy for brazing is a process that requires knowledge and precision. Each material presents unique needs, requiring a tailor-made approach to ensure the maximum effectiveness of the brazing process.
The ability to manage the amount of flux applied to the rod, using a calibrated tool before the coating phase, ensures the same amount of flux for every production batch, thus providing greater control over the process.
It’s essential to analyze the base material to be brazed to determine the optimal amount of flux needed. An excessive amount implies wasted time in post-brazing removal, while an insufficient quantity could compromise the quality of the brazing.
To simplify the choice of the optimal coated alloy, there are several levels of alloy-to-flux ratio:
- Very Low
- Low
- Standard
Let’s see some usage examples.
Copper-Brass
For materials like copper and brass, the “Very Low” solution is the ideal choice. This particular alloy is preferred for its ability to minimize the flux residue, which is relatively easy to remove in these metals. This aspect translates into significant time savings during the post-brazing cleaning phases, making the process more efficient and less labor-intensive.
Copper-Steel
In the case of brazing copper with steel, the “Low” type coated solution proves to be the optimal choice. This alloy provides an ideal balance between the presence of flux and the efficiency of brazing. With a slightly higher amount of flux than the “Very Low” but still below the standard, the “Low” alloy optimizes the quality of brazing while maintaining ease of process management.
Stainless Steel
When it comes to brazing stainless steel, the “Standard” coated products become the prevalent choice. Stainless steel, due to its characteristics, requires a larger amount of flux, especially in the initial heating phases, hence the importance of preventing oxide formation by applying a small amount right at the start of heating. The “Standard” alloy ensures adequate coverage of the brazing area, contributing to a high-quality joint.
Aesthetic Applications
Finally, for those applications where aesthetic appearance is of primary importance, the addition of flux paste can be considered. This option is particularly useful for protecting the brazing area from the appearance of visible oxides after the process, thus ensuring a clean and professional final result.
The optimal choice of coated alloy for brazing requires careful analysis of the base material. By understanding the specific needs of each material, it’s possible to select the most appropriate alloy, ensuring efficiency in the process and excellence in the final result.
Flexibility and Traceability
The availability of different types of coatings allows for a personalized choice based on the applications and habits of customers.
Moreover, the traceability of alloys ensures complete quality control. One of the services available to our customers, upon order and with a minimum quantity to be agreed upon, is the possibility to mark and customize the rods according to your needs.
Conclusion
In conclusion, the careful selection of coated alloys for brazing is more than a technical choice; it’s a strategy to maximize the efficiency, quality, and repeatability of brazing processes.
With careful evaluation of the base material and specific needs, it’s possible to achieve excellent results, reducing processing times and costs, while ensuring a high-quality final product.
Saldobrase, in addition to providing a wide range of coated solutions for brazing, supports you in the design phase and choice of alloys.
Thanks to years of experience and a team of experts, it will be simple and quick to find the optimal solution for every application and brazing process.
