Technologies Archives - Page 28 of 36 - induction heating machine manufacturer

Induction Soldering Copper Tube

Induction Soldering Copper Tube With High Frequency Heating Units

Objective: To heat a section of 3/8″ copper tubing along with a 900 elbow for soldering. The copper tubing is to be used in Ice Machine Evaporator Assemblies, and soldering takes place after the tubes have been placed within the assembly. Heating must take place in a channel type coil to provide easy access, once the tubing has been installed. Solder can be manually fed after temperature
has been reached.
Material: 3/8″ Thin Walled Copper Tubing and 900 Elbow
Temperature: 6000F
Application: Through the use of the DW-UHF-20kW output solid state induction power supply and a unique three (3) turn channel coil, the following results were achieved:
6000F was reached in 10 seconds.
A quality solder joint was observed with adequate flow and surface texture.
Equipment: DW-UHF-20kW output solid state induction power supply including one (1) remote heat station containing one (1) 1.2 μF capacitor, and a unique three (3) turn channel coil.
Frequency: 200 kHz

Induction Soldering Brass Assembly

Induction Soldering Brass Assembly With High Frequency Soldering Units

Objective: To heat a brass bellows and end cap assembly to 4500F for soldering within 20 seconds. Presently, a soldering iron is used to produce the joint between the bellows and cap. The customer requests a quality solder joint with minimal heating of the bellows to prevent annealing and performance losses. Solder preforms, in the form of flat washers, are to be used to complete this application.
Material: Brass Bellows measuring 2″ in diameter Solder Preforms
Cadmium Free Flux
Temperature: 4500F
Application: The DW-UHF-20kW output solid state induction power supply along with a unique three (3) turn double wound helical coil was utilized to achieve the following results:
4500F was reached and solder flow completed in 6.3 seconds.
A quality repeatable solder joint was observed.
Equipment: DW-UHF-20kW output solid state induction power supply including one (1) remote heat station containing one (1) 1.2 μF capacitor, and a unique three (3) turn double wound helical coil with an inside diameter of 0.4″.
Frequency: 307 kHz

Induction Soldering Brass Rings

Induction Soldering Brass Rings With High Frequency IGBT Induction Heater

Objective: To heat 1 3/4″, 3″ and 6″ diameter brass slip rings and a sheathed copper wire assembly to 3600 F for soldering within three (3) to six (6) seconds. Currently production is accomplished by using a soldering iron and stick feeding rosin cored solder. This process leaves unwanted solder on the side of the slip ring where the soldering iron makes contact. The customer would like to see an increase in joint quality without sacrificing time.
Material: 303 Brass Slip Rings of 1 3/4″, 3″ and 6″ diameters. Sheathed Copper Wire Assembly.
Resin Core Solder, 37% Pb, 63% Sn.
Temperature: 3750F
Application: Through laboratory testing, the DW-UHF-20kW output solid state induction power supply along with a unique four (4) turn “ear muff” type coil produced the following results:
Times to reach 3750 F are as listed below:
– 1 3/4″ in 3 seconds
– 3″ in 3-4 seconds
– 6″ in 5 seconds
Adequate solder flow was observed producing a clean joint.
Solder preforms are recommended to speed up production.
Side loading was facilitated by the unique four (4) turn “ear muff” style coil.
Equipment: DW-UHF-20kW output solid state induction power supply including one (1) remote heat station containing one (1) 1.0 μFcapacitor, a 4-20mA input for fast ramp simulation, and a unique four (4) turn “ear muff” style coil.
Frequency: 265 kHz

Soldering Solar Panels With Induction

Soldering Solar Panels With Induction Heating Units

Objective Heat multiple joints on solar flex circuit strips to 500°F (260ºC) within ten seconds for a soldering application.
Material Flexible solar panel, Solder Plus Paste 63NC-A, 0.0625” (1.59mm) thick Teflon sheets
Temperature 500 °F(260ºC)
Frequency 278 kHz
Equipment • DW-UHF-4.5kW induction heating system equipped with a remote workhead with one 1.2 μF capacitor
• An induction heating coil designed and developed specifically for this application.
Process A specially-designed induction coil is used to provide even heat in the area where the wires on the solar circuits overlap. A very light coat of solder paste is applied to the circuit connections and a small amount of pressure is applied to the Teflon sheets to hold the circuits together. Power is applied for 10 seconds to flow the solder paste and bond the wires to the flex circuits
Results/Benefits Induction heating provides:
• Consistent and repeatable results
• Non-contact clean heating
• Flameless process

Soldering Fiber Optic for Hermetic Sealing

Soldering Fiber Optic Cable for Hermetic Sealing With IGBT Induction Soldering Heater

Objective To heat a Kovar ferrule and fiber optic cable to 297°F within 10 seconds for a soldering application, to form a hermetic seal
Material Gold-coated cable, Kovar ferrule, solder and flux
Temperature 297 ºF
Frequency 360 kHz
Equipment DW-UHF-4.5kW power supply with a specially designed induction coil
Process A specially designed, 4-turn “C” shape coil was used to provide uniform heat to the assembly near the joint area. With this design, the coil can be lowered directly onto the joint; it is not necessary to feed the ferrule assembly through the coil. Flux was applied to the assembly where the ferrule and fiber optic cable were to be joined. RF power was applied for 10 seconds, which caused the solder to melt and flow.
Results/Benefits Consistent and repeatable results were achieved with the DW-UHF-4.5kW power supply and a 10-second heat cycle. The solder flowed evenly and bonded the fiber optic cable to
the Kovar ferrule. With the induction coil’s compact design, a very small surface area was heated with pinpoint accuracy.

induction soldering fiber optic cable

Induction soldering fiber optic cable with high frequency induction heating units

Objective To heat a gold-plated ferrule and fiber optic cable to 475°F within 8 seconds for a soldering application
Material Gold-plated ferrule tube, fiber optic cable, solder preform
Temperature 475 ºF
Frequency 270 kHz
Equipment DW-UHF-4.5kW power supply with a specially designed induction coil.
Process A specially designed, two-turn plate concentrator coil was used to provide uniform heat to the fiber optic assembly. The assembly was placed in a specially designed fixture, then placed inside the induction coil. RF power was applied until the solder flowed and created a solid joint.
Results Consistent and repeatable results were achieved using the DW-UHF-4.5kW power supply and induction coil with a 5 to 7 second heat cycle, depending on the type of solder used (see solder chart below).

Induction Soldering Electrical Circuits

Induction Soldering Electrical Circuits Board With High Frequency IGBT Soldering Heater

Objective To heat multiple joints on flex circuit strips to 180-200°F within seven seconds for a soldering application.
Material Copper bonded to polyester flex circuit strips, Solder Plus Paste 63NC-A, 0.0625” thick Teflon sheets
Temperature 183°F
Frequency 278 kHz
Equipment DW-UHF-4.5kW power supply, remote heat station with one 1.2 μF capacitor and a specially designed induction coil.
Process A specially designed induction coil was used to provide even heat in the area where the fingers of the flex circuits overlap. Initial tests were done to establish a heating pattern and determine time-to-temperature. After a very light coat of the solder paste was applied to the circuit connections, a small
amount of pressure was applied to the Teflon sheets to hold the circuits together. RF power was then applied for 6.5 seconds to flow the solder paste and bond the flex circuits
Results Consistent and repeatable results were achieved using the DW-UHF-4.5kW power supply in 6.5 seconds at 183°F.

Soldering Antenna Wire With Induction

Soldering Antenna Wire of Radio With IGBT High Frequency Induction Heater

Objective To heat a coaxial antenna assembly to 600°F within 2 seconds for a soldering application. The goal to improve on an existing procedure with a soldering iron which required 10 to 15 seconds.
Material .250” diameter aluminum antenna assembly, aluminum ferrule, solder paste, temperature indicating paint
Temperature 600°F
Frequency 333 kHz
Equipment DW-UHF-4.5kW power supply, remote heat station with one 1.2 μF capacitor and a specially designed induction coil.
Process Initial tests were conducted with temperature indicating paint to establish a heating profile and determine time-to-temperature. The solder paste was then applied to the antenna assembly and aluminum ferrule. RF power was applied for two seconds to heat and flow the solder joint.
Results Consistent and repeatable results were achieved within the required two-second time frame. A close examination of the solder joint indicated that the solder flowed well and formed a good, solid joint.

Soldering Steel To Brass With Induction Heater

Soldering Steel To Brass With Induction IGBT Soldering Heater

Objective Heat an assembly of small, gold-plated steel connectors to a brass block.
Material Approx. 1/8” (3.2mm) diameter gold-plated steel connectors, 1”(25.4mm) square x 1/4” thick brass block
Temperature 600°F(315.6ºC)
Frequency 240 kHz
Equipment • DW-UHF-6kW induction heating system equipped with a remote workhead.
• An induction heating coil designed and developed specifically for this application.
Process A two-turn helical coil is used to provide uniform heat to parts assembly. Solder paste and flux are applied to the joint area and power is applied for 20 seconds to solder the parts. Proper
fixturing is needed to hold the parts in position.
Results/Benefits Induction heating provides:
• Rapid, localized heating to specific regions of part
• Neat and clean joints
• Flameless processing

Induction Heat Setting

Induction Heat Setting A Shape Memory Alloy With IGBT Induction Heater

Objective Heat a steel die to 975°F (523.8ºC) to set (cure) a shape memory alloy in the correct position.
Material Nitinol wire, 2” (50.8mm) diameter tapered steel die, steel tube to house the die, instant adhesive
Temperature 975°F(523.8ºC)
Frequency 131kHz
Equipment • DW-UHF-6kW induction heating system equipped with a remote workhead containing one 1.0 μF capacitor
• An induction heating coil designed and developed specifically for this application.
Process A five turn helical coil is used to heat the steel die. The Nitinol wire is set into the die and tacked into place using instant adhesive. The die is placed inside a larger steel tube. The die cure is heated to 945ºF (507.2ºC) in 75 seconds. Successful heat setting of the Nitinol wire is achieved in 15 seconds.
Results/Benefits Induction heating provides:
• Fast, accurate, repeatable heating
• Heat precisely delivered only to where it is needed