A very common way to join copper pipe is a method known as bronze welding. Although it is referred to as “welding”, no melting of the parent metal takes place. However, the bond produced is equal in strength and comparable to a fusion weld.
Oxy-acetylene equipment is most satisfactory for this process as it is able to produce and intensely hot flame that gives controlled local heating.
A special brass rod is used to make the joint. This rod consists of approximately 60% copper and 40% zinc. It is necessary to add flux to the joint to enable the rod to adhere to the copper and to prevent oxidation. The flux may be used in powder form by dipping the heated end of the brass rod into it. An alternative method is to mix the flux with clean water to form a smooth paste which can be applied to the weld area and the filler rod with a small brush. Some brass rods have flux impregnated into them by the manufacturers.
The melting point of copper is 1,080ºC while the melting point of the brass filler rod is 850º-950ºC. A slightly oxidising flame should be used.
The main types of bronze welding joints used on copper pipe are:
Note: Many people refer to bronze welding as “brazing”. While the materials and joint process are the same, the technique is slightly different. Brazing uses the principal of capillary attraction in the jointing.
Source: http://local.ecollege.ie/Content/APPRENTICE/liu/Plumbing_notes/Bronze_Welding_M2_U5.doc
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