Brazing vs Welding

If you’re looking to form a permanent joint between two or more metals, there are a variety of ways to do so. However, brazing vs welding services are the most common, and most reliable, choices available. While there are similarities between brazing vs TIG welding, there are key differences that set these processes apart. Chief among them is this: welding involves the melting of two metals to join them, while the metals are not melted during the brazing process.

Welding (TIG Welding)

During welding, metal joints are created through the application of concentrated heat at the joint, which melts the metals, causing them to fuse together. There are several different types of welding that can be performed, depending on what the welder is trying to achieve. However, when we talk about welding services at Axenics, we are referring to the specific type of welding known as TIG welding, or GTAW welding.

TIG welding is one of the best processes for making permanent joints between two materials, creating a stronger bond when compared with brazing.

Brazing

During brazing, the filler metal — which melts at a lower temperature than the base metal — is melted and directed into the joint between the two metals. This occurs through a process referred to as capillary action. Because the filler metal melts at a lower temperature than the base metals, the base metals are not melted during this process. The cleanliness of the metals is extremely important in brazing, as there is less heat applied, and therefore contaminants are less likely to burn out during the process.

The following types of metals are commonly used as filler metals:

• Copper
• Copper-silver
• Brass
• Gold-silver
• Silver
• Nickel alloy
• Aluminum-silicon

Like welding, there are several different types of metal brazing that can be used depending on the project, such as:

• Torch brazing
• Dip brazing
• Furnace brazing
• Infrared brazing
• Salt-bath brazing
• Induction brazing
• Exothermal brazing
• Resistance brazing

Torch Brazing

When we talk about brazing at Axenics, we are referring to the process called torch brazing. Manual torch brazing is often used in cases where the production volume is smaller since it is done by hand and therefore requires more labor and skill. Brazing can also be done with a machine, which reduces labor and skill requirements considerably. Finally, automatic torch brazing can be used for higher production volumes, as the manual labor requirements can almost be entirely eliminated.

Cost Considerations for Brazing vs TIG Welding

When deciding between brazing vs TIG welding, cost is often a determining factor. Brazing typically involves lower heat and can be more cost-effective for smaller or thinner assemblies, especially when working with dissimilar metals. On the other hand, TIG welding often requires specialized equipment and more time, especially for larger or thicker materials. The long-term durability of TIG welding may justify the higher initial investment for certain projects, but brazing offers a budget-friendly option for quick, clean, and precise joins.

Applications Where Brazing vs TIG Welding Shines

Understanding the specific applications where brazing vs welding excels is key to making the right choice. Brazing is ideal for projects that require visually appealing joints, such as delicate piping systems. Its ability to join dissimilar metals also makes it popular in industries like electronics. TIG welding, however, is the go-to choice for heavy-duty applications such as semiconductors and aerospace, where the strongest possible joint is needed to withstand stress and wear over time. Selecting the right process ensures that your final product meets both functional and aesthetic requirements.

Choosing Brazing vs Welding

When deciding between brazing vs welding, why use one process over the other? There are a variety of factors to consider when determining whether to use welding or brazing to join metals, some of which include:

Assembly Size

TIG welding is usually a better choice for projects where larger assemblies are being joined, as brazing works by applying heat to a broader area, which can make it more difficult for the heat to reach the right point of the filler metal.

Thickness of Metals

For thinner base metals, brazing is typically the better option. However, when thicker base metals (0.5 inches or more) are being joined, and you’re considering brazing vs TIG welding, either process can be used.

Joint Shape

For linear joints, brazing is often preferred over welding, as it typically involves less manual work than welding. For fusing spot joints, however, welding is the easier and more economical choice, which also results in a durable joint.

Material Types

When joining two different types of metals, brazing is often the better choice. It will often be more expensive and more complex to join different metal types through welding.

Appearance

If the appearance of the joint matters, brazing is your best bet. Joining two metals through brazing typically produces a neat bead, compared to welding, which results in an irregular bead.

As you can see, there are many advantages to using each type of joining process, depending on your goals and the materials you’re working with. Axenics is happy to help you discuss brazing vs welding services for your project, based on your needs and budget.

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