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

Brazing Aluminum Pipes Assembly With Induction

Brazing Aluminum Pipes Assembly With Induction

Objective: Braze an aluminum assembly to 968 ºF (520 ºC) within 20 seconds

Material : Customer supplied 1.33″ (33.8 mm) O.D. aluminum tube and aluminum mating part ,Aluminum braze alloy

Temperature: 968 ºF (520 ºC)

Frequency 50 kHz

Equipment: DW-HF-35KW,30-80 kHz induction heating system equipped with a remote heat station containing one 53 μF capacitor A two-position helical induction heating coil designed and developed specifically for this application.

Process: Braze material was applied between the tubing and the mating part. The assembly was placed inside the coil and heated for approximately 40 seconds. With a two-position coil, two parts can be heated simultaneously, which means one part would be completed every 15-20 seconds. Braze material was stick fed, which created a good joint. The heating time with two parts being heated simultaneously meets the client’s objective, and represents a significant improvement in regards to speed over using a torch.

Results/Benefits

  • Speed: The recommended approach cut their heating time in half when compared to using a torch
  • Part quality: Induction heating is a repeatable method with more consistency than a torch can generally deliver
  • Safety: Induction heating is a clean, precise method that does not involve an open flame like a torch, which results in a safer work environment

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