Induction Brazing Copper To Copper Parts

Objective Induction Brazing Copper to Copper parts Spacer. The workpieces were heated to 2012˚F (1100˚C) in 1 minutes. Recommended Equipment The recommended equipment for this application is the  DW-HF-45kw induction heating machine Materials: Copper section: 0.55” thick x 1.97” long x 1.18” wide x 0.2” long (14 mm thick & 50 mm long x 30 … Read more

Induction Brazing copper wire to copper cylinder

Objective Induction Brazing copper wire to coppre cylinder with Handheld induction brazing heater Equipment 20kw handheld induction brazing heater Materials Copper wire to Copper cylinder Power: 12 kW Temperature: 1600°F ( 871°C ) Time: 5 sec Results and Conclusions: Induction Brazing successfully in 5 seconds Precise control of the time and temperature Power on demand with rapid heat … Read more

Induction Brazing Brass Studs to Copper Pipes

Induction Brazing Brass Studs to Copper Pipes Objective: Induction brazing brass studs to copper pipes The Client: A manufacturer of coils for industrial heating applications. Equipment: DW-UHF-40KW Induction Brazing Systems – two modules. Materials: Brass stud ( size:  25mm diameter, 20 mm height ) Power: 30 kW The Process:  The main challenge during this induction brazing process … Read more

Induction Brazing copper to copper pipes

High Frequency Induction Brazing copper to copper pipes Process Objective: Induction Brazing copper to copper pipes Equipment: DW-UHF-6KW-III handheld induction brazing heater Materials:  Six Copper pipes (9.5 mm) Power: 6 kW Temperature: 1475 °F/ 800°C Time: 20 seconds Process: The DW-UHF-6KW-III handheld induction brazing system with robot can automatically induction braze multiple joints located in predefined positions. For this brazing application a … Read more

Induction Brazing T Shaped Copper Tubing Assemblies

High Frequency Induction Brazing T Shaped Copper Tubing Assemblies Objective: Test 1 – Induction brazing T-shaped copper tubing assemblies – 3 joints simultaneously Test 2 – Induction brazing copper tubing Industry: HVAC Materials: Copper tubers  6, 8, 10, 12 mm ( 015⁄64, 05⁄16, 025⁄64, 015⁄32inch. ); thickness: 1 mm ( 03⁄64 inch.) Alloy: Cu-P-Ag rings TIP: The use of alloy rings is highly … Read more

Induction Brazing Copper T Pipe With Induction Heating Machine

Induction Brazing Copper T Pipe With Induction Heating Machine Objective Evaluate replacing of flame copper t pipe brazing with induction brazing. Equipment DW-HF-25kw high frequency induction heating machine Materials • Copper main tube – 1.13” (28.7 0mm) OD 1.01” (25.65 mm) ID • Riser tube copper – 0.84” (21.33 0mm)  OD,  0.76” (19.30 0mm)  ID … Read more

Induction Brazing Copper Tube of Heat Exchanger

Induction Brazing Copper Tube of Heat Exchanger Objective Brazing heat exchanger copper to copper pipes Industry Various industries Base material Copper tubes – Diameter / thickness of external tube: 12.5 x 0.35 and 16.75 x 0.4 – Type of assembly: lap joint Other materials Brazing alloy rings Equipment DW-UHF-6KW-III handheld induction brazing heater Key Parameters … Read more

Induction Brazing Copper Assembly

Induction Brazing Copper Assembly With High Frequency Heating Equipment

Objective Brazing a copper pivot assembly
Material Two copper uprights 2” (5cm) wide x 4” (10.2cm) high, copper base 3” (7.6cm) x 2” (5cm) and .5” (1.3mm) thick with 2 channels for the uprights to the slide into, braze shims and black flux
Temperature 1350 ºF (732 ºC)
Frequency 200 kHz
Equipment •DW-UHF-20kW induction heating system, equipped with a remote workhead containing two 1.0μF capacitors for a total of 0.5μF
• An induction heating coil designed and developed specifically for this application.
Process A three turn helical coil is used to heat the base of the assembly. The copper uprights and two braze shims are placed in the grooves in the base and black flux is applied. The assembly is placed in the coil and power is applied for 4 minutes to braze both the uprights in place.
Results/Benefits Induction heating provides:
• Rapid localized heat which can minimize oxidation and reduce cleaning after joining
• Consistent and repeatable joints
• Hands-free heating that involves no operator skill for manufacturing
• Even distribution of heating

Brazing Copper Bars with Induction

Brazing Copper Bars with Induction

Objective: To braze bus bar assemblies together
Material: • 2 copper bus bars 6″ (152.4mm) wide, 2′ (609.6mm)long, 2
copper bars 6″(152.4mm) wide, 18″ (457.2)long & 3/8″ (9.65mm) thick • braze shim preforms and white flux
Temperature: 1292 ºF (700 ºC)
Frequency: 80 kHz
Equipment • DW-UHF-60KW induction heating system, equipped with a
remote workhead containing eight 1.0 μF capacitors for a total of 2.0 μF.
• An induction heating coil, designed and developed specifically for this application

Process: A three-turn helical coil is used to heat the assembly. Three braze shim preforms are placed between the plates and white flux is applied to the assembly. It is heated for 5 minutes to evenly flow the braze alloy. A high current capable, aesthetic looking braze zone is produced.

Results/Benefits Induction heating provides:
• Consistently produced, quality parts
• Heat into the part that is divided equally between the copper pieces, allowing for even flow and consistent use of braze
• Hands-free operation that doesn’t require skilled operators

Brazing Brass To Copper With Induction

Brazing Brass To Copper With Induction

Objective: To braze brass end-connectors to copper tubes used in aircraft assembly air lines Material brass end connectors, copper tubes of different diameters

Temperature 1400 ºF 750°C

Frequency 350 kHz

Equipment DW-UHF-4.5KW induction heating system, including a three turn helical induction coil using two 0.33μF capacitors (total 0.66μF)

Process For smaller diameter parts, flux is applied to the entire part and the copper tube to brass joint is assembled using brazing preforms (allowing for the same amount of braze in each joint). The assembly is placed in the coil and heated for 20-30 seconds reaching a temperature of 1400°F. For larger copper tube assemblies, the same process is used, but the braze alloy is stick-fed to the joint to prevent the alloy from flowing out of the joint. A foot switch control is recommended to enable better control of the process.

Results/Benefits

Economy: Power is consumed during the heating only

Consistency: the results of braze joints are repeatable and uniform