Paste to Preforms
A Prince & Izant high volume automotive customer was experiencing quality issues with their copper brazing paste application. After a materials analysis determined that the paste metal load and viscosity were within specification, an onsite visit was scheduled to observe the brazing process.
Prior to the visit, P&I engineering assessed the factors they needed to consider to evaluate the customer’s specific brazing process. Braze joint design was evaluated and deemed to be appropriate for the application. The following factors were isolated as likely contributors to the fall-out.
Placement of brazing paste
Volume of paste used on joint
P&I Engineering met with the customer to run through the details of the process. First, an overview of the customer’s braze process was provided giving part and product-specific details. Next, our engineering team analyzed the braze process in its production environment. Lastly, P&I engineering provided a detailed report with helpful recommendations for modifying the customer’s brazing paste application process.
The customer was using a manual method of applying copper brazing paste to a vertical braze joint surface which then was brazed in a belt furnace. During the braze cycle, the manually applied paste appeared to lose viscosity and move out of position during preheat causing the customer to repeat the first steps of the process. It was also noted that while the manual application of braze paste was mostly accurate, it was still inconsistent.
We were able to determine that the braze joint orientation was not conducive for the use of the paste. Brazing paste is best suited for horizontal joint applications which is why the customer was seeing the alloy move out of place. In similar cases, P&I has suggested the use of preforms. Preforms better suit vertical braze joint orientations thus, avoiding future reworks due to loss of viscosity and movement. An added advantage of a custom, or standard, brazing preform is that the volume can be controlled consistently throughout every application thus, avoiding any flashing from wetting the surface of the part.
Using a pre-engineered copper preform, the customer was able to avoid all previous braze paste related issues and optimize their manufacturing operations.
Are you experiencing a related issue? If so, contact us to discuss alternatives specific to your needs.
This case study is offered for illustrative purposes only and may not contain all material facts. This case study should not be relied upon for application to your situation or circumstances, even if perceived to be similar. Please consult your PI Engineering or Sales resource for assistance on your particular question or issue.