SOLDERING, BRAZING &

WELDING IN DENTISTRY

DR THULFIQAR
DM
BLOCK 3
GENERALLY
• It is often necessary to construct a dental
appliance in two or more parts and then join
them together by either a soldering or welding
process
• The term soldering ,welding and brazing have
specific meanings in industry
• The term welding is used if two pieces of metal
are joined together directly (generally, but not
always ,without adding a third metal) that is the
metal pieces are heated to a high enough
temperature so they can be attached to each
other
• The word soldering and brazing are used if 2 pieces
of metal are joined by adding a third metal
If the temperature used in the process is below
425°C, the operation is soldering
If the temperature is above 450°C (840°F), the
operation is brazing
In dentistry, the parts are joined at temp above
450°C, so the operation should be called brazing
However, because it is most commonly caused
soldering, the terminology will be used in this
lecture
 KEY TERMS

 SOLDERING (BRAZING) : the joining of metal by melting a

suitable alloy (solder) between the surfaces to be
connected

Soldering antiflux : a material such as iron oxide (rouge)

mixed with chloroform or graphite and placed on a metal
surface to confine the flow of the molten solder

Soldering flux : a material such as borax glass (Na2B4O7)

applied to a metal surface to remove oxides or prevent
their formation in order to facilitate the flow of the solder
Soldering index
1 : a mold used to record the relative position of
multiple cast restoration prior to investing for a
soldering procedure
2 : a rigid resin connection between multiple cast
restoration fixing their relative position prior to a
soldering procedure

Solidification porosity : a porosity that may be produced by

improper spruing or improper heating of either the metal
or the investment
 SOLDERING AND BRAZING
• Both soldering and brazing must be conducted in a
temperature below the solidus temperature of the
substrate metal(s)
• OR simply : the brazing material must have a flow
temperature which is well below the melting point
of the alloys being joined

SOLDERING, BRAZING AND WELDING

• The difference between these two processes and
welding is that welding may not
require a filler metal and the metal
surfaces to be joined will fuse
locally
 SOLDERING PROCESS

• Soldering process involves :

The substrate metal(s) to be joined
(sometimes known as basic metal or parent
metal)
A filler metal (usually called solder)
A flux
A heat source
All are equally important and the role of each
must be taken into consideration to solder the
metal components successfully
SUBSTRATE METAL
Dental casting alloys that can be welded or welded
include :
Gold-based Nickel-based
Silver-based Cobalt-based
Palladium-based Titanium-based

 The composition of substrate metal determine their

metal range

 The soldering should take place below the solidus

temp of the substrate metal(s)
 Thecomposition of the substrate metals determines the
oxide that forms on the surface during heating and if
used, a flux must be able to reduce this oxide, inhibit
further oxidation, or facilitate its removal

 Thecomposition & the cleanliness of the substrate metal

and the temperature to which it is heated determine the
wettability of the substrate by the molten solder alloy

 Thesolder chosen must be the metal at as low as a

contact angle as possible to ensure wetting the joint area

 To prevent flow onto adjacent area, an anti-flux such

as rouge mixed with chloroform or graphite can be
painted on the areas before heating the assembly
SOLDERING FLUX
• The Latin word flux means “flow”.
• Soldering filler metals are designed to melt, wet
the surface(s) of the part to be joined ,and flow
across clean metal surfaces; they cannot wet oxidized
surfaces without the use of a flux
• The purpose of a flux is to eliminate any oxide
coating on the surface when the filler metal is
molten and ready to flow into place & Improve the
flow of a metal

Soldering (Brazing) Filler Metal

• It is unreasonable to expect molten solder to
adequately wet and flow across a metal without
thorough cleansing at the surfaces involved

• The obvious pre-treatment of cleansing and

degreasing are, of themselves, not adequate and
chemical means of removing oxides from the metal
surface as they are formed during the heating
process must be employed

• Thus, a flux is a material which dissolves oxides in

situ during the soldering operation. In general, these
are based on borax/boric acid
 How does The Flux Function?
1. PROTECTOR
It covers the metal surface and prevents oxide
formation
2. REDUCER
Helps to reduce the oxides present on the metal
surface
3. SOLVENTS
It dissolves any oxide presence and removes it
 Flux may be divided into 3 types
1. Type I Surface Protection : Covers the metal
surface and prevents access to oxygen so that
no oxide can be formed
2. Type I Reducing agent : Reduces any oxides
present and expose clean metal
3. Type III Solvent : Dissolves any oxides present
and carries them away
Whatever technique is important to minimize the
amount of flux used because :
• Excess flux may become entrapped within the
filler metal and caused a weakened joint
• Residual flux that is covered with porcelain can
cause discoloration and bubbling of porcelain
• Flux, when combined with metal oxides, forms a
glass during the soldering process that is difficult
to be removed completely
 ANTI-FLUX
• Sometimes, the flow of the solder should be
restricted from parts of the restoration, such as the
margins of the occlusal grooves.
• Chemicals that limit the flow of solder are called
antifluxes
• Flow into these areas can be prevented with an
antiflux material, which should be applied to the
surface before the flux or solder is applied
• Antiflux is used to control the molten solder flow
onto adjacent areas
• Solder does not flow into area contaminated with
graphite; a soft lead pencil is therefore an effective
antiflux
• Other material such as rouge (iron oxide) or whiting
(calcium carbonate) in an alcohol and water
suspension, are effective antifluxes for prolonged
heating or high temperature heating which can burn
off the graphite
• Most common antifluxes used is graphite
• Better fluxes like rouge in chloroform can be used

COMPOSITION OF SOLDERS
∝ Gold ∝ Copper *Gold solders are
∝ Silver ∝ Tin designated by fineness
 SOLDERING TECHNIQUES
• The general technique used in soldering depends on
the degree of precision to which the composition are
to be joined
1. Where high precision is not required , the
components may be FREEHAND SOLDERED
• This involves holding the components in contact
over the heat source by hand, after the flux and
solder have been applied.
• The complete assembly is heated until the solder
flows
1. TORCH SOLDERING (Freehand Soldering)
• Soldering is done under direct flame
• A gas air torch is used for this purpose
• The torch flame has two parts :
i. the reducing part (is at higher temperature)
ii. the soft brush part
• The solder should be melted using the soft brush
flame
• The flame should be constantly swiped over the
solder for a period of 4-5min
• At no point of time the flame should be held in a
stationary position
2. Where a greater accuracy is required, JIG
SOLDERING may be employed and a small jig is
used to hold the components in more accurate
registration before heating

3. For precision soldering, such as the joining the

components of a bridge, the Pontic and abutments
are first placed on the master cast and assembled
with sticky wax (which is kept clear of the surfaces
to be soldered). The temporarily assembled
structure is then invested in dental investment –
INVESTMENT SOLDERING- and the investment
allowed to set . The flux and solder are applied to
the relevant surfaces and the invested device
heated until the solder flows
 SOLDERING INVESTMENT
• It is silica-bonded investments that fused to quartz
• Fused quartz is used because it is the lowest thermally
expanding form of silica
4. INFRARED SOLDERING
• Instead of using a torch to provide heat, an
infrared heating unit is available specifically for
dental soldering.
• The unit uses the light from a 1000-watt,
tungsten-filament, quartz-iodine bulb, which is
mounted at the primary focal point of gold plated,
elliptical reflector
• The material to be soldered is placed at the
reflector’s secondary focal point, at which the
reflected infrared energy of the tungsten light
source is focused
• This equipment can be used for the high-
temperature soldering of alloys for porcelain-
fused-to-metal bridges at 1150°C
• The main problem in the use of this unit is
locating the focal center of the light on the spot
to be soldered. The infrared energy must be
focused on the crowns and not on the solder itself
• Failure to focus on the right spot on the crown
can result in cold joints that are porous

 Infrared soldering
 Used for low fusing connectors
 Good accuracy
 Similar strength as conventional soldering
 Protective eyewear is necessary
SOLDERING FOR METAL CERAMIC RESTORATION
• It is usually done prior to ceramic application
hence it is also known as pre ceramic soldering
• Post ceramic materials are also available
• Pre ceramic soldering is done at a temp of 1075°C
to 1120°C whereas
• Post ceramic soldering should be done at a temp
of 920°C because ceramic may begin to sag at
higher temp
• Post ceramic soldering should be done after
ceramic firing
• Ceramic portions should be finished only after
soldering
 Advantages Disadvantages
Pre 1) The metal framework 1) Difficult to build
Ceramic can be soldered and ceramic on already
Soldering tried in prior to ceramic soldered units
build up
2) Minor casting errors can
also be patched up
during ceramic build up

Post 1) Porcelain can be 1) The metal & porcelain

Ceramic properly build up due may sag at high
Soldering to better access soldering temperature
2) It is more technique
sensitive
3) The solder should be
re-glazed and re-fired
 BASIS OF SOLDER SELECTION
• Certain principles must be observed in selecting
solders, regardless of the application. The ideal solder
includes qualities such as
1) Ease of flow at relatively low temperature
2) Sufficient fluidity to freely flow when melted
3) The ability to wet the substrate metal
4) Strength compatible with that of the structure
being soldered
5) Acceptable colour to give an incospicuous joint
6) Resistance to tarnish and corrosion
7) Resistance to pitting during heating and
application
Dental solders are supplied in a variety of shapes such
as strips, rods, wires, or cubes, each of which is
convenient for certain operations
1. Thin strips are the conventional form for general
applications,
2. Small cubes, approximately 1mm square, are
convenient for soldering a contact area on an inlay
crown
3. Rods are often notched along 2 sides, which permits
them to hold flux better than a smooth form. Also
when melted, the notched forms do not roll back into
a ball as early as smooth form.
Choosing a particular shape depends on the operation to
be performed ; each shape is available in a range of
fineness
 OVERHEATING & UNDERHEATING
• Overheating during the soldering operation will
cause
I. Pits in the solder
II. Penetration or burning through thin sections
III. A loss of strength because of diffusion of the
solder into the other metals or loss of fibrous
microstructure
• Underheating will cause
I. Pitting from the retention of non-melted flux
II. Failure of the solder to flow and adhere to all
surfaces
• Good heating of the surfaces by the solder is
imperative for satisfactory joining of the parts
• Solder that is not well heated tends to “ball” and fails
to spread properly
**Both overheating and underheating will results in
a weaker solder joints. For this reason, the proper
and careful heating and fluxing of the solder are
essential
 Appropriate distance for soldering

• The distance between the parts to be joined

can influence the accuracy of the final
appliance
• If the parts are in intimate contact, they tend
to expand and push apart on heating,
• Whereas if the distance is too great, the parts
tend to draw together as the solder solidifies
• A clearance of a few hundredths of a mm
(0.13mm) between the parts to be joined is
optimal when using the investment-soldering
techniques.
• The thickness can be practically estimated by
the thickness of a typical business card
• When attempting free hand soldering of wires
for orthodontics or other appliances, a closer
adaptation of the parts is possible.
• The shape of the joint and the purpose of
the appliance will ultimately determine the
appropriate distance between the soldered
parts
HEAT SOURCE FOR SOLDERING
1. Hydrogen
2. Natural gas
3. Acetylene
4. Propane Gas
soldering
5. Oven (furnace) soldering
• Performed under vacuum or air
• A piece of solder is placed in the joint space and it is
heated to a standard temperature in the furnace
• Superior joint strength
• Disadvantage – The parent metal will sag or melt if
heated for a long time
 WELDING

• WELDING : the joining of metals by melting the

relevant surfaces together (with or without filler
metal)
• The technique of SPOT WELDING may be used for the
joining of stainless steel components in certain
circumstances
• The spot-welding device consists of 2 copper electrode
between which the components to be joined are placed.
• The components are held in contact under pressure and a
large current is passed across the electrodes and through
the components for a brief period.
• If the electrical conductivity of these components is
relatively low, the heat generated is sufficient to melt the
metal at the point of contact. Hence spot-welding is a
particular example of RESISTANCE WELDING
• Other alloys which are suitable for spot welding include
Co-Cr-Mo and Ni-Cr but the technique cannot be
applied to the gold alloys
 Laser Welding of commercially pure Titanium
• Commercially pure titanium (CP Ti) that is used in
dentistry for crowns, FPDs, & partial denture frameworks
is highly reactive metal in air
• The thin oxide films that forms instantaneously on a
cleaned surface converts this metal from an active to
passive state
• At temperature used for soldering procedures, the
thickness of the titanium oxide layer increases and may
spontaneously debond from the parent metal surface at
temp exceeding 850°C
• Thus, the process of soldering this metal using traditional
torch-soldering procedures is technique sensitive, and the
quality of the soldered joint is quite variable
• To effectively joint titanium components of dental crowns,
FPDs, and partial denture frameworks, the technician can
perform laser welding and plasma welding in an argon
atmosphere
• Since laser welding is associated with a lower thermal
influence on the parts being joined than is plasma
welding, it is the preferred method for dental application
• An advantage of welding is that the joint will be
composed of the same pure titanium as the substrate
components, thereby preserving galvanic corrosion
effects with the prosthesis
Desk type laser welding machine Dental laser welding machine