Group standard VW 01147

Issue 2018-04
Class. No.: 04871

Descriptors: brazing, capillary brazing, capillary brazed joint

Brazing, Capillary Brazing

Previous issues
VW 01147: 2008-11, 2013-05

Changes
The following changes have been made to VW 01147: 2013-05:
– Section 4.1 updated and note 2 added
– Section 4.3: Note 3 added
– Applicable documents section updated
– Section 6 added
– Editorial changes made

Contents
Page
1 Scope ......................................................................................................................... 2
2 Definitions .................................................................................................................. 2
3 Structure of a capillary brazed joint ............................................................................ 3
4 Requirements ............................................................................................................. 3
4.1 Design ........................................................................................................................ 3
4.2 Nickel-based brazing fillers ........................................................................................ 4
4.3 Drawing notes ............................................................................................................ 4
4.4 Manufacturing quality, quality assurance ................................................................... 5
4.5 Tack points ................................................................................................................. 6
4.6 Rework ....................................................................................................................... 6
5 Applicable documents ................................................................................................ 6
6 Bibliography ............................................................................................................... 7

Always use the latest version of this standard.

This electronically generated standard is authentic and valid without signature. Page 1 of 7
The English translation is believed to be accurate. In case of discrepancies, the German version controls.

Technical responsibility The Standards department

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© Volkswagen Aktiengesellschaft VWNORM-2018-02
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1 Scope
This standard specifies the requirements for the design, production, and quality assurance of
brazed joints and high-temperature brazed joints of powertrain components that are implemented
as capillary brazed joints between individual metal parts.
NOTE 1: Examples include exhaust gas systems, exhaust gas recirculation systems, oil lines,
and coolant lines.
The requirements in this standard pertain exclusively to the manufacturing quality of components
without regard to functional characteristics.
The requirements in this standard must be met in their entirety if the standard is referenced in the
component drawing. If the drawings include any deviations from or additions to subsections of the
standard, these deviations or additions take precedence.

2 Definitions
Depending on the combination of material pairing and manufacturing method, mixtures of capillary
brazing and braze welding can occur. Braze welding and capillary brazing differ as follows:

Braze welding
The brazing gap is filled by the force of gravity. The strength of the brazed joint is determined pri‐
marily by the strength of the filler material. Typical manufacturing processes are electric arc braz‐
ing and laser brazing.

Capillary brazing
The brazing gap is filled by capillary action of the liquid filler material. The capillary filling pressure
rises as the width of the brazing gap decreases. The strength of a properly executed brazed joint is
determined exclusively by the strength of the base materials. Typical manufacturing processes are
flame brazing, furnace brazing, induction brazing, and resistance brazing.
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3 Structure of a capillary brazed joint

See figure 1 and figure 2.

Figure 1 – Simple brazed assembly Figure 2 – Cross section through the

assembly

Legend
b Width of the brazing gap t Wall thickness
L Length of the brazing gap 1 Base material
2 Base material affected by the proc‐
ess or the heat-affected zone (HAZ)
3 Diffusion or transition zone
4 Filler material in the brazing gap
Depending on the choice of base material, filler metal, and brazing method, the diffusion zone may
vary with regard to the penetration of the filler into the base material's structure – up to mutual
blending. The absence of a diffusion zone is normally an indication that a brazed joint is faulty (lack
of fusion).

4 Requirements

4.1 Design
The following general standard values for the size of brazing gaps apply when automated process‐
es are used:
Brazing gap width b: Copper brazing filler: 0.01 mm ≤ b ≤ 0.20 mm
Nickel brazing filler: 0.01 mm ≤ b ≤ 0.10 mm
Brazing gaps with b < 0.01 mm may be required in individual cases,
see section 4.2.
Because the capillary filling pressure increases as the gap width decrea‐
ses, the brazing gap must not widen along the path that the brazing filler
flows. In general, the objective must be that the edges of the brazing gap
are parallel.
Brazing gap length L: 4 × tmin ≤ L ≤ 6 × tmin, where tmin is the smallest wall thickness of the brazed
joint.
NOTE 2: The requirements for brazed aluminum joints are specified in component-specific stand‐
ards. DIN EN 14324 [2] contains additional specifications.
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4.2 Nickel-based brazing fillers

4.2.1 General information

When using nickel-based brazing fillers, the brazed joint's quality and usability will be decisively af‐
fected by the filler's tendency to cause segregation of hard intermetallic phases in the material be‐
ing brazed. Pronounced centerline segregation of hard phases must be viewed as being particular‐
ly critical, since it will increase the joint's susceptibility to cracking. Centerline segregation is made
more likely by large brazing gaps in vacuum furnace processes. The type and morphology of these
hard phases are influenced by the following parameters:
– The brazing filler's chemical composition, i.e., the amount of alloy elements contained which
lower the melting point
– The brazing method; especially the choice of continuous furnaces or vacuum furnaces
– Brazing gap width – narrow brazing gaps counteract centerline segregation
These factors cannot be considered separately. Instead, the manufacturer must adjust the brazing
method, brazing filler, and brazing gap in line with the corresponding design on a case-by-case ba‐
sis in order to ensure flawless brazing quality.

4.2.2 Nickel-based brazing fillers under special corrosion conditions

For brazed joints where a nickel-based brazing filler comes into contact with cooling water and/or
gaseous or condensed exhaust gas, only brazing fillers which are free from boron and which con‐
tain at least 18 mass percent of chrome are permissible. In these cases, the preferred alloy ele‐
ments to lower the melting point are:
– Silicon max. 8 mass percent
– Phosphorus max. 7 mass percent
As an alternative with comparable corrosion resistance, iron-based brazing fillers are also availa‐
ble. Their use instead of a nickel-based brazing filler is only permissible after first consulting the
Development department and them then issuing a release.

4.3 Drawing notes

For an example of a drawing note as per DIN EN ISO 2553, see figure 3:

Legend
yyy 3-digit reference number of the manufacturing process as per DIN EN ISO 4063
xxxxx Designation as per DIN EN ISO 17672
Figure 3 – Sample of a drawing note

Alternative drawing note types are permissible as long as they have the same content and provide
clear specifications as in figure 3.
It is not permissible to specify a choice of several brazing fillers on drawings. If fillers or brazing
methods deviating from those used for production are used in the pre-production phase, they must
be identified as a deviation from production standards when delivered.
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Examples of common brazing methods used for production as per DIN EN ISO 4063 are listed in
table 1.

Table 1 – Common brazing methods used for production

Brazing process Reference numbera)
as per DIN EN ISO 4063
Flame brazing 912
Induction brazing 916
Resistance brazing 918
Furnace brazing 921

a) Valid reference numbers at the time of this standard's publication.

NOTE 3: For some brazing processes, it may be necessary to use a flux (see DIN EN 1045 [1]).

4.4 Manufacturing quality, quality assurance

The requirements concerning imperfections defined in DIN EN ISO 18279 apply for manufacturing
quality. The applicable quality level is B as per DIN EN ISO 18279, in the table "Suggestions for
quality limits of imperfections", with the additions described in table 2, if there are no specifications
in the component drawing which deviate from this.
DIN EN 12797 and DIN EN 12799 must be taken into account when designing the inspection pro‐
cesses for brazed joints. From the test methods described there, the supplier and purchaser must
agree on the suitable test method for the particular use case.
The metallographic evaluation of the diffusion zone must be done on polished microsections using
a microscope with at least 200-fold magnification.

Table 2 – Additional specifications, deviating from quality level B

Reference num‐ Designation Deviating specification
ber
2BALF Surface pore Quality level C is permissible.
4BAAA Lack of fusion Only permissible inside and not at the edge of the brazed joint, i.e., areas
with lack of fusion must be fully surrounded by OK brazing.
6BAAA Filler overflow Quality level C is permissible.
5EJAA Angular offset There is an additional condition that the process must not be adversely af‐
fected by the resulting gap geometry.
7NABD Partial melting of the Partial melting is permissible for tack points; see also section 4.5.
base material
5HAAA Rough surface Quality level C is permissible.
6FAAA Insufficient fillet Quality level C is permissible.
5GAAA Irregular fillet Quality level C is permissible.
7SAAA Discoloration/oxidation Permissible where the function of the joint is not adversely affected.
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4.5 Tack points

Tack points are used to affix the individual parts to be brazed during the brazing operation and
have no force-transmitting function.
The following requirements apply to tack points:
– To the extent possible, tack points must be produced using resistance welding. Tacking with
arc welding, especially with filler metal, must be avoided.
– Tack points must be located within the brazing gap and be completely surrounded by brazing
filler once the brazing process is complete.
– Tack points located outside the brazing gap and therefore visible after brazing must be descri‐
bed in the drawing in terms of their position, size, and design.
– Tack points must not impair the function of the component. For components which are subject
to dynamic loads, tack points must not impair the structural durability.
– Tack points must not protrude into flow cross-sections.
If these requirements cannot be met in a particular case, the tack points must be described accord‐
ingly in the drawing.
NOTE 4: Tack points can be avoided in individual cases by using friction locking, e.g., by means
of a snug fit or suitable fixtures, to hold the individual parts in place during pre-assembly.

4.6 Rework
Rework is permissible unless otherwise specified in the drawing.
Reworked components must also meet the requirements of this standard.
Rework must not impair the function or service life of the component.

5 Applicable documents
The following documents cited are necessary to the application of this document:
Some of the cited documents are translations from the German original. The translations of Ger‐
man terms in such documents may differ from those used in this standard, resulting in terminologi‐
cal inconsistency.
Standards whose titles are given in German may be available only in German. Editions in other
languages may be available from the institution issuing the standard.

DIN EN 12797 Brazing - Destructive tests of brazed joints

DIN EN 12799 Brazing - Non-destructive examination of brazed joints
DIN EN ISO 17672 Brazing - Filler metals
DIN EN ISO 18279 Brazing - Imperfections in brazed joints
DIN EN ISO 2553 Welding and allied processes - Symbolic representation on drawings -
Welded joints
DIN EN ISO 4063 Welding and allied processes - Nomenclature of processes and refer‐
ence numbers
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6 Bibliography
[1] DIN EN 1045, Brazing - Fluxes for Brazing - Classification and Technical Delivery Con‐
ditions
[2] DIN EN 14324, Brazing - Guidance on the Application of Brazed Joints