Welding and brazing are two very popular metal joining processes. They have similar characteristics, yet both have distinct advantages and disadvantages. When choosing which process to use on your project, there are many factors to consider. Knowing when to use welding versus brazing can help you choose the right metal joining method for success.
Welding is a metal joining process in which two pieces of metal are heated and fused together using an electric charge or a flame. The resulting joint is very strong; however, welds leave behind marks and may weaken the surrounding material. The process is recommended for metals like steel, stainless steel, aluminum, and copper. Welds are often used for highly structural components, like frames and bridges, because of their strength and reliability.
Brazing is also a metal joining process, typically involving two pieces of metal that are heated to a high temperature and then cooled to form a joint. The resulting joint is typically not as strong as a weld but is corrosion and heat-resistant. The process is often used to join metals with different thermal expansion coefficients, like steel and aluminum, as it produces a well-sealed connection. It can also be used to join dissimilar metals, like steel and titanium, which have different melting points. While brazing is a popular choice for many commercial and industrial applications, it is not often suitable for structural components or very thin pieces of metal due to its lower flexural strength.
When deciding between welding or brazing, the type of metal being joined should be the first consideration. Welding works best for heavy-duty, solid pieces of metal like steel. It is not a good choice for thin pieces of aluminum or other metals as the heat required for the welding process can lead to warping and other defects.
Brazing, on the other hand, is ideal for joining two thin pieces of metal together. It can also be used to join two pieces of metal with different thermal expansion coefficients. The heat required for brazing is much lower than welding, so it is less likely to produce defects.
The desired strength of the joint should also be considered when deciding between welding and brazing. Welding produces a much stronger joint than brazing, making it the best choice for highly structural components or applications where maximum strength is required. However, a brazed joint typically provides greater corrosion and heat-resistance than a welded joint.
In addition to the type of metal and the desired strength of the joint, the cost of the process should also be considered when deciding between welding and brazing. Welding may be more expensive than brazing due to the higher heat required, the powerful equipment needed, and the additional time needed to complete the process. Brazing is often the more cost-effective option for smaller jobs as it requires less time and produces fewer defects.
Choosing between welding and brazing can be a daunting task, but following these guidelines can help make the decision easier. Welding is ideal for solid, heavy-duty pieces of metal and for joints requiring maximum strength. Brazing is best suited for thin pieces of metal, for joining two dissimilar metals, or for providing greater corrosion and heat-resistance. Ultimately, the type of metal being joined, the desired strength of the joint, and the cost of the process should be taken into account when deciding which joining process is best.
