This article presents an overview of resistance brazing (RB) used for many applications involving small workpieces, for small joints that are part of very large equipment, or for low-volume production runs. It lists the advantages and limitations of RB and outlines the factors that contribute to high quality in an RB joint. The article discusses the classification of RB such as manual RB or automatic RB. It describes the selection of metal electrodes and filler metals for RB. The filler metals include silver alloys, aluminum-silicon alloys, and copper-phosphorus alloys.

This article provides information about the selection of brazing processes and filler metals and describes the brazing (heating) methods, including manual torch brazing, furnace brazing, induction brazing, dip brazing, resistance brazing and specialized brazing processes such as diffusion and exothermic brazing. The article explains joint design, filler materials, fuel gases, equipment, and fluxes in the brazing methods. The article also describes the brazing of steels, stainless steels, cast irons, heat-resistant alloys, aluminum alloys, copper and copper alloys, and titanium and titanium alloys.

This article describes the physical principles of brazing with illustrations and details elements of the brazing process. The elements of brazing process include filler-metal flow, base-metal characteristics, filler-metal characteristics, surface preparation, joint design and clearance, temperature and time, rate and source of heating, and protection by an atmosphere or flux. The article explains the different types of brazing processes: manual torch brazing, furnace brazing, induction brazing, dip brazing, resistance brazing, infrared (quartz) brazing, exothermic brazing, electron-beam and laser brazing, microwave brazing, and braze welding.

Copper, copper alloys, and precious metals are probably the most easily brazed metals because of their resistance to oxidation at high temperatures. This article provides a brief discussion on the metallurgy of copper, copper alloys, and precious metals and discusses the filler metals, brazing fluxes, joint clearance and design, and different brazing processes used in brazing of copper, copper alloys, and precious metals.

Resistance soldering (RS) can be applied to electrically conductive materials that allow the passage of electric current. The process can be used for selective spot soldering of small components, for the soldering of closely placed parts on an assembly, or for heat restriction when necessary. This article explains that the RS process can be used in all soldering operations and with all solderable metals. It provides information on the applications, preassembly practices, the equipment used and the training required for soldering personnel.

This article focuses primarily on the various steps involved in the brazing of heat-resistant alloys (nickel- and cobalt-base alloys). The major steps include the selection of brazing filler metals, surface cleaning and preparation, brazing processes and their corresponding atmospheres, and fixturing. The article also provides an overview of the brazing of blow-alloy steels and tool steels and oxide dispersion-strengthened alloys.

This article describes the secondary operations for cemented carbide parts, namely, diamond grinding, honing, electrical discharge machining, and brazing after sintering to achieve desired results, such as specified size, shape, edge condition, and surface finish.

The various methods of furnace, torch, induction, resistance, dip, and laser brazing are used to produce a wide range of highly reliable brazed assemblies. However, imperfections that can lead to braze failure may result if proper attention is not paid to the physical properties of the material, joint design, prebraze cleaning, brazing procedures, postbraze cleaning, and quality control. Factors that must be considered include brazeability of the base metals; joint design and fit-up; filler-metal selection; prebraze cleaning; brazing temperature, time, atmosphere, or flux; conditions of the faying surfaces; postbraze cleaning; and service conditions. This article focuses on the advantages, limitations, sources of failure, and anomalies resulting from the brazing process. It discusses the processes involved in the testing and inspection required of the braze joint or assembly.

This article is a compilation of definitions for terms related to welding fundamentals and all welding processes. The processes include arc and resistance welding, friction stir welding, laser beam welding, explosive welding, and ultrasonic welding.

Brazing technology is continually advancing for a variety of metals including aluminum and its alloys and nonmetals. This article discusses the key physical phenomena in aluminum brazing and the materials for aluminum brazing, including base metals, filler metals, brazing sheet, and brazing flux. It describes various aluminum brazing methods, such as furnace, vacuum, dip, and torch brazing. Friction, flow, induction, resistance, and diffusion brazing are some alternate brazing methods discussed. The article reviews the brazing of aluminum to ferrous alloys, aluminum to copper, and aluminum to other nonferrous metals. It also discusses post-braze processes in terms of post-braze heat treatment and finishing. The article concludes with information on the safety precautions considered in brazing aluminum alloys.

This article describes the factors considered in the analysis of brazeability and solderability of engineering materials. These are the wetting and spreading behavior, joint mechanical properties, corrosion resistance, metallurgical considerations, and residual stress levels. It discusses the application of brazed and soldered joints in sophisticated mechanical assemblies, such as aerospace equipment, chemical reactors, electronic packaging, nuclear applications, and heat exchangers. The article also provides a detailed discussion on the joining process characteristics of different types of engineering materials considered in the selection of a brazing process. The engineering materials include low-carbon steels, low-alloy steels, and tool steels; cast irons; aluminum alloys; copper and copper alloys; nickel-base alloys; heat-resistant alloys; titanium and titanium alloys; refractory metals; cobalt-base alloys; and ceramic materials.

Corrosion is often thought of as rusting, the process of deterioration undergone by a metal when it is exposed to air or water. This article provides the fundamentals of joints corrosion and primarily addresses the various forms of corrosion observed in brazed and soldered joints and their causes. It describes the role of proper brazing procedures in controlling corrosion. The article concludes with information on the corrosion resistance of various brazing alloy systems.

This article discusses different types of joining processes, including welding, brazing, soldering, mechanical fastening, and adhesive bonding. It examines two broad classes of welding: fusion welding and solid-state welding. The article discusses the process selection considerations for welding, brazing, and soldering. It also describes joint design considerations such as selection of weld joints and welds.

The quality of brazed stainless steel joints depends on the selection of the brazing process, process temperature, filler metal, and the type of protective atmosphere or flux. This article provides a detailed discussion on the applicability and brazeability of stainless steel and lays an emphasis on the selection of suitable filler metal, brazing processes, and its corresponding furnace atmosphere for brazing different grades of stainless steel. The types of brazing processes include torch brazing, furnace brazing in different atmospheres (dissociated ammonia, dry hydrogen, and vacuum atmosphere), dip brazing in salt bath, and high-energy-beam brazing. A complete list of the typical compositions and properties of standard brazing filler metals for brazing stainless steel is also provided.

Wrought 4xxx alloys (extrusions and forgings) exhibit high surface hardness, wear resistance, and a low coefficient of thermal expansion. This article provides a summary of brazing filler metals used to join brazeable aluminum-base metals. It contains tables that list the nominal composition and filler-metal alloys of 4xxx series used in structural forms.

This article provides a discussion on filler metal selection, brazing procedures, and brazing equipment for brazing refractory metals. These include molybdenum, tungsten, niobium, and tantalum, and reactive metals. Commercially pure and alpha titanium alloys, alpha-beta alloys, zirconium alloys, and beryllium alloys are some reactive metals discussed in the article.