Brazing Aluminum Tubing to Aluminum Parts

Objective The objective of the application test is induction brazing aluminum tubing to aluminum parts in less than 15 seconds. We have aluminum tubing and an aluminum “receiver”. The brazing alloy is an alloy ring, and has a flow temperature of 1030°F (554°C). Equipment DW-HF-15kw induction heating machine   Induction heating coil Materials • Aluminum … Read more

Induction brazing aluminum pipes

Objective High frequency induction brazing aluminum pipes Equipment DW-UHF-6kw-III handheld induction brazing machine Materials Аluminum to aluminum tube Flared at interface 0.25” (6.35mm) Brazed to steel tube 0.19” OD (4.82mm) Power: 4 kW Temperature: 1600°F (871°C) Time: 5 sec Results and Conclusions: Induction heating provides: Strong durable joints Selective and precise heat zone, resulting in less part distortion … Read more

Induction Brazing Aluminum Tube T Joints

High Frequency Induction Brazing Aluminum Tube T Joints Objective Induction brazing of multiple in line aluminum T tube joints for less than 10 seconds each and brazing an aluminum fitting into an aluminum tube 1.25″ (32mm). The application is about brazing of an aluminum tube assembly consisting of two parallel tubes with outer diameter of … Read more

Induction Brazing Aluminum Automotive

Induction Brazing Aluminum Automotive 

Objective: Heat aluminum for an automotive brazing application
Material: Aluminum tubing 0.50 (12.7mm) dia, an aluminum boss 1” (25.4mm) long, flux filled braze rings
Temperature: 1200 ºF (649 ºC)
Frequency: 370 kHz
Equipment • DW-UHF-10KW induction heating system, equipped with a remote workhead containing one 1.0μF capacitors for a total of 1.0 μF
• An induction heating coil designed and developed specifically for this application.
Process A multi turn pancake coil is used to heat the joint between the aluminum tubing and boss. The joint heats to temperature in 1.5 minutes and the braze ring melts forming a clean brazed
joint.
Results/Benefits Induction heating provides:
• Hands-free heating that involves minimal operator skill for manufacturing
• Flameless application
• Reliable, repeatable aesthetically pleasing braze joint
• Even distribution of heating

Brazing Aluminum to Copper Tubes with Induction

Brazing Aluminum to Copper Tubes with Induction

Objective: To heat an aluminum manifold to 1050 ºF (566 ºC) for a brazing application:

Material :

  • Cu tubes (3/4″/19mm)
  • Cu tubes (5/8″/15.8mm)
  • AI tubes (3/8″/9.5mm)
  • AI manifold (5/8″/15.8mm)
  • AI manifold (3/4″/19mm)
  • Lucas-Milhaupt Handy One alloy 30-832
  • Braze wire

Temperature 1050 ºF (566 ºC)

Frequency 260 kHz

Equipment DW-UHF-10KW 150-500 kHz induction heating system equipped with a remote heat station containing two 1.5 μF capacitors.

  • A two-turn oval helical induction heating coil designed and developed specifically for the aluminum assembly
  • A five-turn helical induction heating coil designed and developed specifically for brazing the Cu tubes to AI joint assembly

Process Braze : pre-forms were designed to fit the aluminum tubes. Then the four aluminum tubes were placed into the manifold and the assembly was inserted into the coil. The assembly was heated for approximately 70 seconds, at which point it reached the targeted temperature and braze flowed. For the Cu tubes, a braze pre-form was also designed for them, wound around the tubes, and the assembly was placed inside the coil. The heating cycle time was approximately 100 seconds. Some joints required stick feeding of braze to fill the entire joint area due to the braze wire size. If the cycle time was lengthened, the need for stick feeding would be eliminated.

Results/Benefits: Precise, repeatable heating:

  • The client wanted more precise and repeatable heating than a torch could deliver, which induction was able to achieve .
  • Temperature control: Induction allows for superior temperature control when compared to other methods, including a torch, which the client desired

 

Induction Brazing Aluminum Pipes

Induction Brazing Aluminum Pipes

Objective: Brazing two aluminum pipes simultaneously to an aluminum evaporator core

Material 2 aluminum pipes 0.72″ (18.3mm) diameter, evaporator core 9.88″ x 10.48″ x 1.5″ thick (251mm x 266.3mm x 38mm), braze rings

Temperature 610 ºF (321 ºC)

Frequency 250 kHz

Equipment • DW-UHF-20KW induction heating system, equipped with a remote workhead containing two 1.5μF capacitors for a total of 0.75μF • An induction heating coil designed and developed specifically for this application.

Process A four turn helical pancake coil is used to heat the 2 pipes simultaneously. Three braze rings are placed on each joint and power is applied for 90-100 seconds to create a leak proof joint on both pipes. Narrative • Customer is requiring a 40 seconds heat time for both brazes. In order to meet this requirement 3 units will be utilized to braze 2 joints each for a total of 6 joints in 90-100 seconds. The customer is currently using a flame process which can burn away the thin flange at the joint area and create scrap parts. By switching to induction for this application the customer is decreasing their scrap parts and also increasing their quality and production rate.
Results/Benefits Induction heating provides:
• Repeatable leak free joints
• Increased part quality, less scrap
• Hands-free heating that involves no operator skill for manufacturing
• Even distribution of heating