Solder Erosion Effect
Solder erosion effect: the unwanted dissolving and removal of base material by the molten solder due to excessive exposure time or temperature. This leads to cross-section weakening of the part.
Physico-chemical mechanism of action
Erosion of the base material occurs when the molten filler metal stays in contact with the base material too long or acts at too high temperatures. This dissolves and wears away the metal crystals under the influence of chemical and mechanical forces. This process can be caused by continuous movement of the welding torch (e.g., during welding) or by static load.
Metallurgical relevance & risks in welding
Erosion weakens the cross-section of the part, which impairs mechanical properties and shortens the life of the weld. It can also lead to irregular weld bead shapes and increased susceptibility to cracking and fracture. In extreme cases, the base material can be completely penetrated.
Workshop practice & actions
To minimize erosion, take these steps:
• Use a suitable protective agent or a protective film on the base material to prevent contact between the filler metal and the base metal.
• Reduce the contact time of the filler metal by optimizing welding speed and correct welding parameters (e.g., voltage, current).
• Make sure the welding torch is cleaned regularly to avoid contamination.
• If needed, use a heat shield or mask to control and lower the temperature of the filler metal.