GENERAL APPLICATION GUIDE
A. Joining Wire to Wire
(.001" to .375" diameter)
Welding is the most spectacular. Flame is played upon the larger
wire with the smaller wire shielded behind the larger wire. As
the larger wire melts, its heat transfer to the smaller wire
causes melting of the smaller wire, and fusion takes place. Another
method is to bring the larger wire to the molten stage and rapidly
push the smaller wire (cold) into the melt, where it will also
melt and fuse. Use care to prevent overheating and burning of
the smaller wire. In brazing or soldering, heat is played upon
large wire, braze or solder is added, and the small wire is pushed
into the puddle. Flame should not normally be directed onto the
solder or braze.
| Applications | Methods |
| Thermocouples | Weld, Silver Braze, Solder |
| Wires to Headers | Weld, Silver Braze, Solder |
| Wires to Terminals | Weld, Silver Braze, Solder |
| Coil Wire | Weld |
| Wire to Tubing | Weld, Braze, Solder |
| Stranded Wire to Stranded Wire | Weld, Silver Braze, Solder |
| Stranded Wire to Solid Wire | Weld, Silver Braze, Solder |
| Large Wire to Small Wire | Weld, Silver Braze, Solder |
B. Joining Wire to Sheet
and Terminals
Flame should be directed mainly onto the part presenting the
greatest mass of heat sink - the lesser part is introduced to
the greater part when the greater part has reached (approximately)
proper working temperature. This important precaution permits
parts to reach proper working temperature simultaneously - neither
one over-heating.
| Applications | Methods |
| Thermocouples to Test Piece | Weld, Silver Braze, Solder |
| Wires to Cases and Chassis | Weld, Braze, Solder |
| Wires to Relay Blades | Weld, Silver Braze, Solder |
| Component Leads toTerminals | Solder |
| Wires to Castings | Weld, Silver Braze |
| Lead Wires to Circuit Boards | Silver Braze, Solder |
| Wires to Couplings (Slip Rings) | Weld, Silver Braze |
| Wires to Connectors | Solder |
C. Joining of Sheet
Stock (.001" to .109")
Lower melting materials are best suited for welding. Higher melting
materials require brazing or soldering. The Flux-flame (flux
added to booster alcohol) comes into its own on this application
when brazing the higher melting metals such as steel.
| Applications | Methods |
|
| Hermetic Sealing | Weld, Braze, Solder | |
| Metal Tape to Itself | Weld, Braze | |
| Fabrication of Enclosures | Weld, Braze, Solder | |
| Foil to Itself | Weld, Silver Braze, Solder | |
| Repair of Lead Electrode Plates | Weld, Solder | |
| Bimetal Stock | Silver Braze | |
| Tank Linings | Weld |
D. Joining of Wire Mesh
(.0005" to .375")
Best results on fine wire are obtained when using a flux/solder
paste mix. Finely divided solder (or braze material) particles
in this substance form minimum heat sink and allow joining without
overheating the wire in order to bring solder to flowing state.
| Applications | Methods |
| Wire Mesh to Mandrels | Weld, Silver Braze, Solder |
| Wire Mesh to Wire Mesh | Silver Braze |
| Wire Mesh in Vacuum Tubes | Weld, Silver Braze |
E. Metal Cutting (.0005"
to .015")
Oxidizing flame (without booster) is best because true cutting
is really a matter of high speed oxidation. Atmospheric oxygen
does the job when metal to be cut is brought to brilliant white
heat.
| Applications |
| Thin Stock Sheets |
| Wire Mesh |
| Wires |
F. Glass and Plastic
Working
Chemistry of the materials to be worked is important - Pyrex
glass for instance works best under booster flame with borax
added to booster alcohol (1 teaspoon to 1 pint). Flame resistant
plastics perform best for joining applications.
| Applications |  |
| Laboratory Apparatus | |
| Welding Thermometer Tubes | |
| Fusion of Sheet Stock |
G. Glass to Metal Seals
Heat the glass first to the following stage, then heat metal
to dull red as it comes in contact with glass puddle. Push metal
into glass - then flow glass around metal to form hermetic seal.
| Applications |
| Wire to Glass Blocks |
| BiMetal Strips into Glass Blocks |
| Salvage of Header Pins |
H. Hole Drilling (.0005"
to .020" Sheet Stock and .001" to .020" Wall Thickness
Tubing)
Highest temperature flame (without booster) and high pressure
(20 ounces and up) is best to produce minimum hole size. Slow
flame produces extensive adjacent overheating which is often
undesirable.
| Applications |
| Quartz |
| High Melting Metals |
| Ceramics |
| Glass |
| Hard to Drill Metals (Abrasive Materials) |
I. Annealing
Controlled heat input to part is necessary. This input is varied
by one or more of three methods.
1. Control time of flame application.
2. Control flame size.
3. Control distance of flame from workplace.
| Applications |
| Spring Wires |
| Flat or Coil Springs |
| Spot Welds |
J. Quartz Working
Quartz requires temperatures up to over 6000 degrees F. By filling
the booster with pellets of silica gel or dry crystals of calcium
chloride monohydrate or using drying tower, an extremely dry
gas will be produced which will improve the results. do not use
booster with methyl alcohol as flame temperature will be too
low.
| Applications |
| Lamp Tubes |
| Weldments (Structural) |
K. General Heat Source
Important factors for this application are: high reliability,
low operating cost, requires only water and electricity, unidirectional
heat, cleanliness, portability, and complete control over flame
size and velocity.
| Applications |
| Spectrographic Sample Burning |
| Melting of High Temperature Plastic |
| Maintaining Temperature in Die Casting Metal and Plastic |
| Wire Stripping |
| Curing Deposited Carbon for Resistors |
| Repairing Printed Circuit Boards |