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Calculating the Amount of Brazing Alloy to use

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Calculating the Amount of Brazing Alloy to use

Braze joints are strongest at about 0.0005” (1/2 of one –thousandth of an inch) but this is not a good standard for two main reasons:

  1. As the braze joint gets thicker it provides significant impact protection.  In saws, drills, etc.  You need to draw compromise between braze joint strength and impact protection.  Generally 0.003” to 0.006” is a good place to start testing.  Then try more and less until you find what works best in your application.   
  2. In tool manufacturing it is generally very hard to hit 0.0005” exactly and often the joint has no braze alloy or not nearly enough braze alloy and the joint fails.   There are more tips and instructions on how to create proper Braze joints in our Brazing Section. 

We developed a concept we call “average silver depth.”  Pretend the rounded hump is actually square and flat.  Multiply the length, width and depth of braze alloy you want.  This gives you the desired volume.  Then take the volume of a one inch piece of braze alloy wire and use that to find the length of wire needed. 


1/4" Masonry Drill - Brazing Area Calculations

This is a bit more difficult than a saw tip or router blank so we will use it for an example.  



  1. Find the areas of the rectangle and the triangle.  Multiply by two because you want brazing alloy on each side.  Add the area of the bottom. 
  2. Multiply the area by the desired thickness of 0.004" to get the desired volume.  
  3. Take the brazing alloy wire and find the area of the cross section which is the area of a circle.
  4. Divide the desired area by volume by the area of the brazing alloy wire and this will give you the length of wire you need.       


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