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NEW 22 CARAT GOLD SOLDERS This Article Is Taken from Chapter 5 of Lengths NEW 22 CARAT GOLD SOLDERS This article is taken from Chapter 5 of lengths. The brazing operation is by a powder method, which involves tumbling the chain in a Principles of Brazing. The chapter non-gold, silver-base braze powder. It is then re- is titled “Filler Metals for Carat Gold tumbled in talc to remove braze powder adhering and Hallmark Silver Jewelry.” to exposed surfaces, leaving it only in the gaps of the links. The chain is then brazed by passing the prepared chain through a belt furnace in an inert David M. Jacobson atmosphere. Wembley, England Giles Humpston Brazes for gold jewelry Most readers will be familiar with the term carat. Tessera Inc. It is a unit for measuring the purity of gold and, San Jose, California quite separately, as the mass of precious stones. On the scale of gold purity, 24 carat (karat in the razes for jewelry, silverware, and objets United States and Germany) represents pure gold. d’art merit separate consideration from Thus, an 18 carat gold alloy contains 18/24 (i.e., industrial brazing alloys because, in ad- 75%) weight fraction of the precious metal. dition to providing joints that are mechan- Quality items of jewelry are made with yellow Bically durable (in terms of their strength, ductility, gold of 18 or higher caratage. The word carat ac- and wear resistance), they must satisfy two addi- tually derives from the Arabic word quirrat, tional and fundamentally different criteria spe- meaning seed, and the weight of a semiprecious cific to this usage: They must match the caratage carob seed was taken as one carat. Nowadays, by and the color of the components. The surface tex- definition, a one carat gemstone has a mass of 0.2 ture of the solidified filler metal and its resistance gm (0.00705 oz). to corrosion also must not differ greatly from that Brazes for carat gold jewelry must meet or ex- of the joined parts, so that any joints remain es- ceed the fineness/caratage of the component piece sentially invisible to the naked eye (Fig. 1). parts of the assembly for it to meet the national Some jewelry manufacture is highly automated, fineness/caratage standards and marking or hall- like much other industrial assembly. A good ex- marking regulations for jewelry. ample is silver and gold chain production, in which the links are formed, brazed, and finished New 22-carat gold solders on fully automatic machines at many tens of links The term “solder” in jewelry manufacture is per second. equivalent to the term “braze” in metallurgy. Gold In earlier times, chain was handcrafted, and solders of 22 carat composition based on the ter- premium-quality items are still made this way. nary combination of gold, silicon, and germanium Chain represents the oldest form of jewelry, and take advantage of the deep eutectic valley that ex- foxtail-style chain dating from 2500 B.C. has been tends through the ternary phase diagram. This excavated from the city of Ur. It remains one of eutectic, which intercepts the 22 carat fineness, is the most popular styles, although well over 200 illustrated in Fig. 2. In common with the industry other varieties of chain are currently available. standard gold solders in the electronics industry, In mass-produced chain making, the links are foil can be manufactured by hot rolling and wire fashioned from stock wire or tape. This may be by hot extrusion. Strip casting is another possi- a homogeneous precious alloy or cored with base bility, but strip cast foils of carat gold-germanium- metal. If the latter, during the chain-forming silicon alloys are brittle, because the hard process, the core is dissolved out, prior to brazing, metastable intermetallic Au3(Si,Ge), forms when thereby reducing weight. The links are formed the cooling rate exceeds 5°C/s. into chain by machines and removed as cut Ductility can be restored by heat treating the Fig. 1 — Gold brazes, known as solders in the jewelry foil at 285°C (545°F), which is 0.9T solidus, for industry, must provide joints that are mechanically 20 minutes or more (Fig. 3). No satisfactory flux durable and that also match the caratage and the color of has been identified for gold-silicon-germanium the gold components. alloys or, indeed, for the industry-standard gold- ADVANCED MATERIALS & PROCESSES/MARCH 2006 41 silicon and gold-germanium eutectics. Silicon and germanium-silicon alloys can be made more tol- germanium react with oxygen when heated to erant to the joining environment by protecting the form stable refractory oxides on the free surfaces, solder foil or wire with a coating of gold that is which impede wetting by these alloys. Rosin impervious to oxygen. fluxes have been found to be ineffective in either An alternative approach that is widely prac- dissolving or disrupting these oxides, and stronger ticed in the electronics industry with the con- acids or halogens corrode the alloys, owing to the stituent binary solders is to dip preforms of the large electrochemical potential difference between filler metal in hydrofluoric acid (then rinse and gold on the one hand and germanium and silicon dry) immediately prior to use. This treatment on the other. strips both the oxide and the near-surface non- metal, and hence significant reoxidation does not Flux mixtures occur until more of the nonmetal has had an op- Fluxes based on mixtures of salts and hydrox- portunity to diffuse through and oxidize at the ides of the alkali metals show some promise and surface. The shelf life of solder so prepared is have the merit that the residues are soluble in short, typically 30 minutes at room temperature, water. The fluxing mechanism, in this case, is be- but is adequate for handcrafting of jewelry. lieved to involve a combination of oxygen exclu- sion and chemical attack of the refractory oxides. Solder foil Both the jewelry and the electronics packaging in- A 22 carat solder foil has been successfully de- dustries would benefit from more research in this veloped for yellow gold jewelry alloys. It com- area. prises a core that is slightly deficient in gold and The binary gold-silicon and gold-germanium also the light element silicon, with respect to the alloys can be successful as solders if the joining eutectic valley linking the Au-3Si and Au-12.5Ge operations are carried out in a nitrogen atmos- binary eutectics. It is coated with a gold plating phere with low oxygen and water vapor content to inhibit formation of dross and thereby facili- (~5 ppm in total). These and the ternary gold- tate wetting and spreading of the solder. The thinness of the plating means that preforms Ge have a finite shelf life, although it is several 20 months. The core alloy is of composition 90Au- 8Ge-2Si, which has a melting range of 362 to 382°C 18 (684 to 720°F). The application of the gold coating 16 of sufficient thickness raises the overall caratage > to 22, and reduces the melting range to 362 to 14 370°C (684 to 698°F). In jewelry terminology, the 12 361°C two-metal structure of the preforms is referred to as a “double” or “onlay.” 10 The requisite protective atmosphere conditions for this solder (~5 ppm combined oxygen and 8 water vapor) can be made by drawing nitrogen Germanium content, wt.% — gas off a liquid nitrogen tank. The inlet needs to 6 be made leak-tight, but the outlet beyond the 22 carat line mouth of the furnace can be left open, provided 4 the nitrogen flow rate exceeds 0.5 m/s. This gas 2 Eutectic velocity is faster than back diffusion, and hence 363°C line the flowing nitrogen maintains low oxygen and 1064 °C water vapor levels in the furnace. Because of good 2 4 6 8 10 Au Si Silicon content, wt.% —> heat transfer from the heating elements via the ni- trogen at near-atmospheric pressure, the soldering Fig. 2 — Liquidus surface of the gold-germanium-silicon cycle on jewelry items can be completed rapidly. system. A continuous eutectic valley links the two binary eutectic points. This eutectic valley crosses the 22 carat fine- 250 ness at the composition 91.6Au-6.8Ge-1.6Si. 200 Gold-base eutectic solders* 10 150 Eutectic Melting point, composition Actual caratage Color °C (°F) 100 Au-3.2Si 23.2 Light yellow363 (685) Hardness, HV Au-12.5Ge 21.0 Pale yellow361 (682) 50 Au-20.0Sn 19.2 White 278 (532) –1 –0.5 0 0.5 1 1.5 2 Au-24.0In 18.2 Gray 458 (856) Heat treatment time, log h Au-25.4Sb 17.9 White 360 (680) Fig. 3 — Progressive recovery of the ductility of strip-cast * Some of these are used for engineering applications, and are possible candidates as filler metals for jewelry. foils of the 22 carat gold solder 91.6Au-6.8Ge-1.6Si, during heat treatment at 285°C (545°F). 42 ADVANCED MATERIALS & PROCESSES/MARCH 2006 Although the furnacing require- tests, designed to assess the suscep- ments are modest, they are more so- tibility of joints to degradation from phisticated and expensive in terms skin acids and household chemicals, of capital expenditure than a simple did not reveal any deficiencies in the set of torches, which means that the joints. main area of application would be for jewelry manufacture offering suf- ficient profit margins. For more information: Giles Humpston, The joint quality resulting from Tessera Inc., 3099 Orchard Drive, San this plated solder foil at a process Jose, CA 95134; tel: 408/894-0700; e-mail: temperature of 425°C (800°F) is ex- [email protected]; www.tessera.
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