If you’re looking for a reliable way to join metals together, you may have heard of fusion welding and brazing. But what exactly is the difference between these two welding processes? In this blog post, we’ll break down the differences between fusion welding and brazing so that you can determine which one is right for your project.
Fusion welding is a process used to permanently join two pieces of metal together by melting them into one another. This process requires great heat, usually in excess of 2000°F. The high temperature melts the metals being joined, allowing them to mix and form a molecular bond when they cool down. Fusion welding is commonly used with aluminum, stainless steel, and other common metals.
The most popular type of fusion welding is MIG (metal inert gas) welding, which uses an electrical current to generate heat that melts the base materials together. The other popular option is TIG (inert tungsten gas) welding, which uses an electric arc to generate heat instead of an electrical current. MIG and TIG are excellent choices for welders needing a strong weld without much cleanup required after the job.
Brazing is another process used to join two pieces of metal together without melting them into one another. Instead, it relies on filling any gap between the two pieces with molten filler material that binds them together when it cools down. Unlike fusion welding, brazing does not require extreme temperatures—typically no more than 1200°F—making it easier to use on materials like copper or brass that are sensitive to higher temperatures. It also produces less smoke compared to fusion welding since there’s no melting involved in the process.
Difference Between Fusion Welding and Brazing
Advantages of Fusion Welding
Fusion welding has several advantages over brazing:
- Fusion welds are stronger than braze welds.
- Fusion welding can join thicker pieces of metal than brazing.
- Fusion welds are less likely to leak than braze welds.
- Fusion welds are less likely to crack than braze welds.
Advantages of Brazing
Brazing has several advantages over fusion welding:
- Brazing is faster than fusion welding.
- Brazing does not require as much heat as fusion welding, which makes it easier to control.
- Brazed joints are less likely to distort than fused joints.
- Brazed joints are easier to repair than fused joints.
Disadvantages of Brazing
There are also some disadvantages to brazing:
- Fused joints are stronger than brazed joints.
- Brazed joints are more likely to leak than fused joints.
- Brazed joints are more likely to crack than fused joints
Whether you choose fusion welding or brazing will depend on your particular project and its needs—both processes have their advantages and disadvantages depending on what kind of metal you’re working with, how strong of a joint you require, and other factors. But now that you know the basics about each process, you can decide which technique will work best for you!
A passionate metal industry expert and blogger. With over 5 years of experience in the field, Palak brings a wealth of knowledge and insight to her writing. Whether discussing the latest trends in the metal industry or sharing tips, she is dedicated to helping others succeed in the metal industry.