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Best Practices for Brazing Connections

  • September 2026
  • Number of views: 22
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Chase Fell
Jay Industrial Repair
Docena, Alabama 

Brazing is the most common joining process used in electric motor and generator connections for AC machines. Whether reconnecting stator coils, joining rotor conductors, or repairing hydro generator windings, a properly executed braze will provide excellent electrical integrity and mechanical strength. Brazing is the process of joining two or more metals by melting a filler metal that flows into the joint by means of capillary action. The braze filler metal has a lower melting point than the adjoining metal. Brazing does not melt the work piece. Soldering is similar to brazing, but with soldering, the melting point is much lower than with brazing materials. And the soldered joint is mechanically not as strong as it is with braze. 

Many brazing failures can be traced to a short list of preventable mistakes. Poor cleaning, improper heating, excessive joint gaps and incorrect use of flux are among the most common causes of weak or unreliable braze connections.

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ANSI/EASA AR100

More information on this topic can be found in ANSI/EASA AR100

EASA Technical Manual

More information on this topic can be found in EASA's Technical Manual
  • Section 2: AC Machines

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