When it comes to electrical contacts, there are several popular methods of fusion. Most people are familiar with soldering, fusion welding, and adhesive bonding. While these are often the appropriate methods to use, brazing is an often-overlooked option.
Brazing is the process of fusing two metals at a much higher temperature than is ordinarily used. Specifically, the metals being joined together are heated at over 100 degrees above the typical temperature welding temperature. In some cases, brazing is an ideal choice for electrical contacts.
Since the brazing filler metal, which is used to join the two objects, is heated at such a high temperature, it melts much more thoroughly. In doing so, it seeps into even the smallest pores on the electrical contact. Upon drying, the brazing filler metal has reached so far into the object it was applied to that the two have become inseparable.
If the electrical contacts you’re combining are part of an object or appliance that is expected to undergo a significant amount of stress, then brazing is an ideal process. Because the melted metal can get such a strong grasp on the electrical contact, it can withstand a high level of stress without bending or breaking. This might apply more to commercial products than to household products.
If you’re combining two objects with large surface areas, brazing might be the best approach. Soldering might prove too difficult with two large-scale items, and because of the amount of surface area using an adhesive is both difficult and inefficient. The most effective approach is to use a brazing filler metal and placing it between each object, permanently fusing the two. In addition to this being the ideal method of joining two large surfaces, it’s also the most cost-effective.
Two different types of metal are most easily fused through the brazing process. Soldering can prove difficult when the metals are dissimilar. Since the brazing process involves the introduction of a liquid form of a third metal, it will dig into both metals and form a permanent bond.
Although soldering, welding, and adhesives have their place in combining electrical contacts, using brazed contacts has proven highly effective in certain scenarios.