Posted by admin on Tuesday, February 10, 2009 · Leave a Comment
I think each of the other answers is pretty much a little bit correct at least.
Welding melts the metals at the joint using very high temperatures. Essentially the metal from the two parts is blended by heat. This works best with metals that have properties that are suitable to the a molten phase that does not quickly become too liquid. Basically if the metal melts too easily it will become a liquid and run out of the weld area. Steel being a material that is commonl welded. Properly done a weld is just as strong as the metal being joined. However, the higher heat of welding can change the material properties if you aren't carefull. Also, welds are commonly performed on like materials only.
Brazing uses a braze alloy that become liquid at a moderate temperature to join two other metals. These metals can be the same or dissimilar. The joined materials are NOT molten in this case, but as I mentioned the braze alloy is liquid and flows between the joint. A very neat process and one that I work with daily. Properly performed brazed joints are actually stronger than the work pieces they joined! Brazing only has minimal impact on material properties (although it can change them). Braze alloys can be expensive. Copper alloys are commonly brazed, particularly since copper's properties make it very difficult to weld.
Soldering uses an alloy that is liquid at relatively low temperatures to join two other metals. It has the least impact on the base materials, but also provides the weakest joint. Its particularly useful when heat can damage or distort the materials being joined. Electrical components are commonly soldered to avoid heat damage.
If you want to learn more, search for phase diagrams of various metal alloys, as well as changes that might occur from thermal changes. There really is a science behind why each process is used and they generally can't be used interchangably.
By the way, I see more and more where structural adhesives are being used to replace these metal bonding methods. Ease of application and no clean-up or reduced clean-up are some of the reasons. But I'm not yet convinced of their strengths.
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