Pin brazing is a hassle-free, safe, and highly effective method for creating electrical connections to ductile iron and steel pipelines. This technique is particularly useful when the object needs to be cathodically protected or earthed. Unlike traditional welding methods, pin brazing preserves the metallurgical properties of the base metals while ensuring a strong, reliable connection.

Pin brazing was invented back in the 1950’s and ever since has been the primary choice for attaching cables and earthing metal objects within the cathodic protection industry. Its versatility and ease of use make it especially popular for pipeline installation, sacrificial anode attachment, and other industrial applications.

Advantages of Pin Brazing Over CAD Welding

One of the key advantages of pin brazing is that it does not alter the metal’s structure or its metallurgical properties. In contrast, with CAD welding, high temperatures can compromise the strength and durability of the metal, which is a significant drawback. Pin brazing, by comparison, works at much lower temperatures—rarely exceeding 650°C—therefore minimizing any adverse effects on the base metal.

In addition, another benefit is the speed and simplicity. It can be completed in virtually any weather conditions, and the equipment is lightweight and portable. Furthermore, pin brazing requires minimal training. Most operators can learn to use the equipment effectively with just one hour of training, unlike the more intensive training required for CAD welding.

How Does Pin Brazing Work?

Pin brazing is based on electric-arc silver soldering. The process uses a specialized pin brazing unit, which is a lightweight welding device. When the operator pulls the trigger of the pin brazing gun, it completes an electrical circuit and releases a direct current (DC). This current melts the flux inside the brazing pin, soldering the connection between the two metal objects.

The entire process takes only one to two seconds. Once the brazing is complete, the pin is mechanically or electrically broken, leaving a homogeneous electrical connection between the two metal surfaces. This reliable bond is crucial in applications where electrical continuity is needed, such as cathodic protection systems.

Why Temperature Matters

One of the most significant advantages of pin brazing is its lower operating temperature. Traditional welding methods, such as CAD welding, use much higher temperatures, which can exceed 1,000°C. As a result, these higher temperatures can affect the structural integrity of the metals involved, causing long-term problems like material weakening or cracking. However, the lower temperatures in pin brazing ensure that the metals maintain their properties, thereby making it a safer and more effective method for certain applications.

Where can we use it?

Pin Brazing is ideal for use in several specific industrial areas, including:

• Insulated pipe sections (joints): Connect cables to insulated joints without damaging the coating.
  
• Connection of measuring cables: Monitoring pipeline conditions and ensuring the integrity of cathodic protection systems.
  
• Installation of sacrificial anodes: Attach sacrificial anodes and protect pipelines from corrosion in cathodic protection systems.
  
• Bonding zinc bracelets to subsea pipelines: Bond zinc anodes to pipelines for subsea cathodic protection.

Versatility and Safety in Cathodic Protection

Pin brazing is widely considered to be the most versatile and safe method for creating electrical connections in the cathodic protection industry. Its ability to maintain the metal’s original properties while providing a secure connection makes it the go-to solution for protecting pipelines, vessels, and other metal structures from corrosion.

By ensuring that the cables and anodes are securely bonded, pin brazing contributes to the long-term durability and performance of cathodic protection systems.

You can see our Pin brazing equipment here