Advanced Brazing Training

Braze training can make a tremendous difference in the quality of the operation. To learn more or to schedule a training call 1-800-346-8274 or email sales@carbideprocessors.com.

Deliverables on Previous Projects

Eliminate tungsten carbide breakage entirely

Reduce tungsten carbide braze failure to six sigma (3 parts per million)

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Eliminate rework
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Improve bond strength by 40% eliminating braze failure

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Double tool run time
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Increase coolant life from 2 weeks to six months

Eliminate safety and health risks due to Cadmium

Reduce safety and health risks due to Cobalt

Reduce costs of labor and materials by 60%

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Smoother finishes
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More precise cutting
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Brazing Program Impacts
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Cost reduction
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Cross-functional team building
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Greater tool reliability
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Safety and health
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Environmental
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Brazing Program Requirements

Cross functional teams: Interdisciplinary, Interfunctional, and Concurrent engineering

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Hard Data - Numbers
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Prints and specifications for tool bodies

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Tool performance data
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Comparison of good to bad tools
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Tool running instructions
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Employee commitment to change
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Employee ability to change
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Management buy-in
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Analyze current data
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The topics covered are as follows:

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Safety and health
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Physics of brazed tools 
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Braze alloy chemistry 
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Differences in brazing alloys 
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Parts cleanliness in brazing 
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Braze joint clearance - Designing braze joints for tensile strength

Designing braze joints for impact protection

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Temperature control 
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Using SPC in brazing

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Determining what to measure
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Establishing upper and lower SPC standards

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Establishing production floor testing 
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Incorporating SPC in the production process

Identifying braze failure

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Compiling braze failure data
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Analyzing braze failure from data
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Tool tipping materials - Tungsten carbide grades, uses and selection

Grinding operations as related to brazed tools

Identifying improved tool performance

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Gross breakage
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Microfracturing
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Measuring run life
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Quality procedures

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Establishing inspection points
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Establishing inspection parameters
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Documentation 
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Standardizing procedures
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Establishing written procedures
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Special emphasis on:

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Temperature
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Most common causes of braze failure in order.

Wrong Braze alloy is the major reason for breakage and loss

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Improper fluxing
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Switching from Black Flux to White Flux can cause tip loss

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Watery Flux  
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Dried or old flux 
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Improper braze joint thickness
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Too thin a braze joint
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Uneven solder – poor tip placement
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Uneven solder – poor wiping motion
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Tip placement
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Improper cleaning
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Improper brazing temperature
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Underheating the solder
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Overheating the solder
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Colors in the solder – burnt solder can have a green or pink/rose color to it

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Gas entrapment
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Wrong flux
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Underheating
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Overheating
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Surface condition of the tip
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Overheated tungsten carbide
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A combination of things 
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SPC Considerations in Braze Failure

Engineering sets a needed specification for brazing of 100

We set the SPC limits from 110 to 130

The system is engineered to deliver 150 when everything runs right but we only need 100.

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For impact
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Fluxing 
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Heating
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Part movement during brazing
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Example

If everything works right we get a value of 150 and we need 100

If one part is at 90% we get 90% of 150 which is 135.  We need 100 and we are good

If 2 parts are at 90% then we get 90% of 90% which is 81%.  81% or 150 is 121.50 and we are good.

3 parts at 90% is 72.9% of 150 which is 109.35

4 parts is 65.6% of 150 = 98.4 and we have tool failure

Brazers in saw mills

Inspect incoming tool bodies (saws, shapers, routers, band saw, planer knives, etc.,)

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Accept or reject the bodies
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Repair bodies
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Tension
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Flatness
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Cracks 
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Wear
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Resurface body before brazing
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Specify tool tip material
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Clean tool tip material
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Flux
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Braze
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Inspect
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Track tool performance
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Track each tool individually
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Specify tool design and re-design
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Maintain equipment

Sun Studs article in Timber Processing magazine

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Exact placement of induction heating
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Computer controlled brazer
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Digital feedback screen
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Video inspection system
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Critical Points

Tools

All tools are inspected against original specifications

All tools are brought back to original specs before re-use

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Within one half thousandth 0.0005”
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Fit and flatness – Darryl’s question about gaps

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Ribbon is flat
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Tungsten carbide is flat
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If body is flat then flux and dirt are only possible source of problems

Material selection

Different materials used depending on task to be done

Heating

Calculated, measured, preset exact heating

Tungsten carbide position +/- 0.001” / 0.002”

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Black Flux
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Video inspection system
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Calibration marks
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No Cadmium 
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Tungsten carbide grinding

Precision automatic machines

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CNC
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“Screw” type
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Cam controlled
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All hydraulic
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All flutes ground exactly equally 
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Records

Records kept of each tool by serial number

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Every tool has a computerized history 
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Equipment maintenance

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Serviced and checked daily
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Also weekly and monthly
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Annual total rebuild 
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Performance

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In the cut saw monitoring systems
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Amperage draws to determine edge condition

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Specified run-times for tools
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2.5 hours for band saws
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5 hours for round saws 
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Recommendations

Start keeping records

Measure what you think might be important to see if it really is.

Add or delete recording keeping as it seems important

Get original specifications where available

Test to see if those specifications are still valid

Do not use out of spec parts and materials

You can make good tools out of bad parts sometimes but the odds are against you

Same with equipment

Find out how the equipment is supposed to perform

Figure out or find out how to test to see if it is performing properly

Set upper and lower limits for acceptable performance everywhere:

Roughly:  Upper limits that are too high mean too much expense, Lower limits too low mean tool failure

Figure out easy, simple plant floor measurements for performance

Some tools are bad – eliminate those – you may not know why but the record will show that some break more than others

Compare good tools to bad tools every way you can

Test to see which differences are important

Work with other people in other departments

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Brazing Program Impacts
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Cost reduction
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Cross-functional team building
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Greater tool reliability
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Safety and health
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Environmental
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Carbide Processors, Woodworking Tools

(800) 346-8274

Free UPS Ground Shipping on Orders over $150!
Over 18,000 Items Discounts up to 40% off Retail

Our Newsletter

Advanced Brazing Training

Carbide Processors, Woodworking Tools

(800) 346-8274

Free UPS Ground Shipping on Orders over $150!Over 18,000 Items Discounts up to 40% off Retail

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Advanced Brazing Training

Free UPS Ground Shipping on Orders over $150!
Over 18,000 Items Discounts up to 40% off Retail