Welding Brazing and Soldering in Manufacturing Process Lab Report

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Introduction Welding, brazing and soldering is an important aspect of manufacturing process. In order to further cement our understanding of those techniques mentioned above and supplement the topics covered in lecture three experiments were conducted. 1. Welding (stick welding/thermit) 2. Brazing 3. Soldering Purpose: Like any other experiment, the purpose of this particular lab is to better comprehend exactly how and why one technique or joining process is preferred over another and what situations that may be the case. Issue: Given two dissimilar metals how exactly are you going to join them together such that their bond is really strong. The scope of the experiment we conducted included fitting two copper tubes into each other and fastened by means of filler metal. This process is made possible by capillary action between the faying surfaces of the metal pieces being joined together, much like how water is drawn up in a straw in opposition to external forces such as gravity, the filler metal is drawn into a properly fitted joint. The second experiment we conducted is joining two empty aluminum beer cans by means of welding. Since aluminum has a relatively low melting point, we used low temperature torch and a tin rod with flux to join the two ends of the aluminum beer cans. Next, we watched in awe as the instructor demonstrated a well done exothermic brazing. Two multi-wire cupper were joined together through chemical reaction. A sensitive amount of aluminum and iron oxide powder were poured onto the joint of the two cupper wires. The mixed powder was ignited at about 1400 °C. as the name suggests, this produce an enormous amount of heat. Enough to melt the filler metal and wet the metal interface surfaces, thus creating a strong physical bond between the two joining cupper wires. 1 Test & Evaluation Needed materials for this procedure: • • • • • • 2copper tubes, 1 copper cleaning brush, Flux Solder (filler metal) Sand paper Low temperature torch Procedure(soldering) 1. 2. 3. 4. 5. Clean the copper the copper tube to get off any residue Gently grind with a sand paper around the joining interface Out flux around the joining interface to prep it for soldering Manually the two copper tubes into the each other Turn on the torch and heat up all around the faying surface which you want the solder to melt on 6. When you heat it long enough, starting putting the solder (filler metal) in one spot and heat it till it starts to melt then go around the copper tube and you have formed a ring around the copper tube and let capillary action do what it does. Needed materials for this procedure: • • • • A mixed powder of aluminum and iron, Two thick copper wires Brazing unit Work station 2 Procedure (thermit welding) 1. 2. 3. 4. 5. Bring the two ends you want to join Using a brazing unit to hold them together, pour the finely mixed powder Ignite the powder until it melts the filler metal Give it a few minutes the exothermic process to cool down Gently break off the residue to give the brazed area a smoother surface Needed materials for this procedure: • • • • • • • • Welding rod High temperature torch Acetylene air Oxy-acetylene Two steel plates Welding glasses (shade 10) gloves Work station Procedure (stick welding) 1. Out on your glove and welding glasses 2. Use a hard surface to hold the two steel plates together 3. Turn the acetylene-air and the oxy-acetylene on and adjust the flame until you get a strongly protruding blue about half an inch long 4. If you are right handed, hold the torch on your right hand and the welding rod on the other hand 5. A pick a reasonable spot to start the welding and heat it, then bring the rod into the flame until it melts and creates a small puddle 6. Slowly and meticulously trace the flame to the other end of the joining interface 7. If the welding rod gets stuck, gently heat it again until it gets off 3 Needed materials for this procedure: • • • • • 2 empty soda/beer/pop cans 1 rod Flux or fluxed rod is good as well 2 masses to hold together the cans Work station Procedure (soldering) 1. 2. 3. 4. Place the ends of the two empty cans Use 2 heavy masses to hold them in place Heat you the area you want to join Aluminum easily melts, make sure to evenly distribute the heat around the area you want to solder 5. Once its evenly distributed, place the solder (filler metal) in one spot until it melts and even solder all around the joining interface 6. If you need to rotate the joining cans, use a glove and don’t burn your hand Findings These procedures include procedures that we actually performed and a procedure we observed. We performed a soldering and stick welding. we observed the thermit welding. Soldering: We found that aluminum melts quiet easily and one needs to be cautious to make sure the cans aren’t melted while joining them or filling a whole. Brazing: the exothermic process happens really fast and it actually explodes Stick welding: I found this to be the hardest because the welding rod gets stuck quiet often which messes up the fine welded line at the end of the process. Turning on and off the torch using the acetylene are and the oxy-acetylene isn’t easy by any means. I had a tough time managing the flame to a size flame and strong enough to melt the welding rode. 4 Interpretation & results The overall results were positive and quiet engaging. The strength of the base metal has an effect on the strength of the brazed joint. Some base metals are also easier to braze than others. that was case with aluminum brazing also known as hard soldering, I found myself melting the base metal while trying to melt the filler metal but because aluminum has a relatively temperature it is difficult to braze the joint without damaging the base metals. I realized the difference between brazing and soldering. brazing occurs at high temperatures whereas soldering occurs at low temperatures. Flux plays an integral part in soldering. it will keep the base metal clean proper flux the filler metal. Conclusions & Recommendations These experiments were critical to better understand some of the technique of joining two similar or dissimilar metals or even filling a hole in a metal. Soldering is better suited for low temperature metals such as aluminum. Flux is needed to ensure that the soldering process goes as smooth and cleans as possible. Brazing is another important technique primarily employed for metals that aren’t suited for welding nor soldering. like copper pipes and so on. There are different methods of brazing a copper metal. One of them is fitting copper tubes into each other and fastening them by means of heating then melting a filler metal around the joining interface and letting capillary action fill the rest. When you take them apart, you will notice a nicely done shine aluminum (filler metal) painted on the interface between the two copper tubes. Thermit welding is probably my favorite and a beauty to watch. You pour aluminum metal and iron oxide and ignite. This chemical reaction is so hot that it melts even steel. This is generally used for fixed broken piped or broken metals. Lastly, stick welding for the first time was very difficult as the melting rod was constantly moving and getting stuck. This technique is not suited for thick metals. If I had to something differently, it would be to bring my note book and take notes as the instructor explains because there is so much more to these important techniques that what I have summed up in my report and I look forward to learning much more in this lab to better comprehend the content covered in class. 5
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Running head: LAB REPORT

Lab report
First name Last name
Institution

LAB REPORT

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Introduction.
For a manufacturing process to be complete Welding, Brazing and soldering play a significant
part in the process. To additionally solidify our comprehension of those systems referenced
below and supplement the areas tackled in-class experiments, it was essential to carry out three
experiments on:
1. Welding (stick welding/thermit)
2. Brazing
3. Soldering.
Purpose/Objective.
The primary purpose of this specific lab experiment is to examine precisely how and why
one technique/process or joining process is favoured over another and what circumstances that
might be the situation.
Issue.
The primary goal of this experiment is to examine how two different metals could be
joined to form a strong bond. In this particular experiment, it involved joining two copper tubes
together and soldered by way of filler metal. This procedure is made conceivable by capillary
activity between the faying surfaces of the metal pieces being combined, as water is drawn up in
a straw contrary to external forces, the filler metal is brought into an appropriately fitted joint.
In the second experiment, it involved welding two empty aluminium beer cans to join
them. We employed the use of low-temperature heat to join the two cans since aluminium has a

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LAB REPORT

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relatively low melting point. Also, a tin rod with flux was used to combine the two ends ...


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