Induction Soldering Copper Wires

Induction Soldering Copper Wires With IGBT High Frequency Heating Units

Objective Soldering two copper wires to pre-installed turrets on a copper buss bar
Material Solder dipped copper/nickel buss bar, 2 tinned stranded copper wires, brazing stick
Temperature 446 ºF (230 ºC)
Frequency 230 kHz
Equipment • DW-UHF-6kW induction heating system, equipped with a remote workhead containing one 1.2μF capacitor.
• An induction heating coil designed and developed specifically for this application.
Process A four turn split helical coil is used to solder the buss bar assembly. The 2 copper wires are applied to the turrets and power is applied for 30 seconds. The brazing stick is fed by hand to the heated parts and the braze flows evenly, creating the joint.
Results/Benefits Induction heating provides:
• Reduced solder time
• Even distribution of heating
• Joint to joint consistency

Induction Soldering Brass To Copper

Induction Soldering Brass To Copper With IGBT High Frequency Heating Equipment

Objective To heat brass and copper for soldering application on medical equipment
Material Brass ring, brass and copper pieces 5.11” (130mm) long, 4.3” (110mm) OD & 0.3” (7mm) at thickest point and solder rings
Temperature 392 ºF (200 ºC)
Frequency 306 kHz
Equipment • DW-UHF-10 kW induction heating system, equipped with a remote workhead containing two 0.33μF capacitors for a total of 0.66μF
• An induction heating coil designed and developed specifically for this application.
Process This process is completed in two steps that use a 3 turn helical coil. The first process is to solder the brass ring to the copper piece which takes 85 seconds. The second step is to solder a large brass piece to the first assembly. This process takes 50 seconds for a total process time of two minutes 15 seconds.
Results/Benefits Induction heating provides:
• Hands-free heating that involves no operator skill for manufacturing
• Even distribution of heating
• Faster process time, current process takes 5 minutes
• Consistency by using solder rings

Induction Soldering Copper Tap

Induction Soldering Copper Tap on a Speaker Ring with IGBT Induction Heater

Objective Heat copper tab until the solder reflows.
Material Copper tab 0.25 X 0.25 inch square about 0.05 inches thick. Lead free solder material (higher melting temperature than regular solder.)
Temperature 500 ºF for 1.25 seconds
Frequency 286 kHz
Equipment DW-UHF-4.5 kW, 150-400 kHz solid state induction heating system equipped with a remote heat station containing one 1.2 μF capacitor and a specially-designed work coil..
A multi-turn helical coil about 3/16 inch internal diameter made out of 1/16 inch diameter tubing.
Process Solder wire is fed onto speaker tab area using an automatic wire feeder. It is then heated to re-flow the solder.
Results/Benefits With an efficient coil design induction heating easily reaches the desired reflow temperature in a very short amount of time.