Brazing is the process of joining two wires, rods, or conductors using a nonferrous filler metal at temperatures above 427°C (800°F).
Brazing creates a strong, permanent bond between metals by heating a filler alloy above its melting point and drawing it into the joint through capillary action. Unlike welding, the base materials are not melted, preserving their properties. Common filler metals include copper, silver, and aluminum alloys. In wire and cable, brazing provides durable, conductive joints that withstand vibration, corrosion, and thermal cycling, making it ideal for industrial and high-performance applications. Compared to soldering, brazed joints achieve greater mechanical strength and reliability, ensuring long service life in demanding electrical and structural environments.
Brazing processes and filler materials are defined by AWS (American Welding Society), ASTM (American Society for Testing and Materials), and ISO (International Organization for Standardization). Electrical brazed joints may also follow UL (Underwriters Laboratories) guidelines for safety and performance.
Brazing dates back thousands of years as a method for bonding metals in early craftsmanship. In modern industry, it became critical for creating precise, durable joints in aerospace, automotive, and electrical systems. Its role in wiring expanded with industrial manufacturing, where reliable conductor bonding was required for performance and safety.