Working with Brass

How to Cut Brass

Start by using paper, a cereal box, or spare cardboard to cut out templates for layout. This ensures that all components will be uniform. You can model your design in a CAD/CAM program if desired, especially with a project that is complex and precise.

Now you have two options, you can either glue the templates to the surface then remove them at the end of the work. Or you can secure the template on the brass sheet stock and draw an outline of the template with a fine-tipped marker. Mark the centers by punching holes with a center punch.

Cut along the outline of the brass sheet with aviation snips. If you prefer, a hacksaw, saber saw, jigsaw, or bandsaw will work. Blipvert suggests using a power jigsaw to turn corners in order to preserve the extra brass stock segments. After the shape is cut, deburr and file the edges.

How To Drill Brass

A step drill makes the neatest holes, and a chain drill is a good tool for creating larger holes. Also, make sure you use a round file to smooth the holes after you drill them. However, a regular drill is a solid alternative. You can deburr the holes using the deburring tool if you choose. When drilling brass be sure to check the drill manufacturer’s table for the appropriate brass drilling speed. For example, Noresman Drill & Tool recommends 150 – 300 sfm (surface feet per minute).

How to Bend Brass

Sheet metal is traditionally bent with a benchtop or floor sheet metal brake, sheet metal pliers, or a press. Blipvert uses a vise with soft jaws, which he made from HDPE plastic scrap, along with a ball peen hammer for small bends. With these tools, clamp the brass squarely in the vise and gently hammer and mold the sheet until it reaches the desired bend.

If you have tight tolerances, keep in mind that the minimum bend radius tends to be the thickness of the stock. Bending a larger radius, on the other hand, can be done by clamping a solid rod of wood or metal next to the sheet and forming it around the bend. Bends for longer sheets that can’t fit within the vise jaws can be done by clamping two pieces of angle iron around it and lightly using a hammer to work it into the desired bend. Lastly, if accidental bending occurs in a section of the sheet you wish to keep straight, simply hammer the section on a flat surface until it reaches its original form.

How to Weld Brass

Brass can be more difficult than other metals to weld, primarily due to the presence of zinc. However, by following a few simple steps welding brass can be an easy and fun task.

First, you should find out the zinc percentage in the material you are dealing with as it will impact your weld. Since zinc has a lower melting point than copper, overheating the alloy can lead to porosity and cracking.

You should use Oxyacetylene as your shielding gas to protect the material from the atmosphere. Zinc tends to have a poor reaction to the environment and releases toxic and dangerous fumes. Porosity can also be a side effect of ineffective shielding, so make sure you set yourself up for success.

Next, you will need to use flux to promote the fusion of metals better when working with Brass. Mix the flux with water to create a paste and coat the brass surfaces that you are welding with the flux paste. (Use a brazing flux that is specially designed to work with Oxyacetylene gas.)

Keep the acetylene gas on low to create a barrier while increasing the oxygen supply. This ensures there will be enough oxygen to develop a coating on the Brass. This coating prevents any harmful fumes from escaping during your weld.

Lastly, choose a welding tip that’s larger than you would for welding brass to steel. You will need higher heat conductivity for the former procedure

How to Solder Brass

When soldering brass, Blipvert uses a propane torch because this is the easiest way to join brass. Butane torches also work.

Use a silver solder, also called plumbing solder. This material has no cadmium, lead, or other undesirables. It is also harder and stronger than the more common lead solders. Because of this, silver is the ideal solder for working with brass.

Also, apply solder separately to each part for the best results. This is a process known as tinning. Next, make sure you heat the parts, not the solder itself.

Here are key points to consider:

1. It should fit snugly with no ragged edges or gaps.
2. Use flameproof clamps. Alternatively, you can use wire to tie pieces together. You can also clamp some wood between the metal and the clamp itself. That extra wood acts as a buffer and makes sure that your clamps don’t get hot quickly and burn you.
3. It is important that your surface is free of oxides in order to produce a good joint. Therefore, using flux to rid of any oxide and prevent new oxide layers from forming during soldering is important. Something as simple as a Q-tip can be used to apply the flux where it is needed. Generally, it is a good idea to use a liquid flux. If you must use a paste flux, do so sparingly.
4. Use a face mask or well-ventilated area when soldering with brass.
5. Even though you won’t melt brass while soldering, heating it to higher temperatures or for a long period can leech the zinc out and weaken the metal. Therefore, use just enough heat and heat the metal evenly by moving the torch back and forth along the joint to drive off the flux. Repeatedly remove the torch and touch the solder wire to the joint. If done right, the solder wire will stick but not flow in. Continue to evenly heat the brass until the solder pulls into the joint when they touch. Follow up with a few more passes to make sure you have a secure connection.
6. Brass doesn’t quench harden so you can cool in down in water.
7. After soldering, remove any remaining acid residue. Simple dish soap, a toothbrush, and water will do this.
8. Learn to accept slight discoloration. Because of the heat, some darker discoloration is unavoidable. Revive the brassy color by polishing the metal with sandpaper or “Bar Keepers Friend” powder.

Many thanks to our fantastic and knowledgeable customer Blipvert for this information about working with brass. If you are looking for more information about welding brass, check out our blog post about welding copper and its alloys here!