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Technology of Induction Forming Steel Plate

Technology of Induction Forming Steel Plate

Triangle heating technique using a gas flame is used to deform steel plate in ship construction. However, in the flame heating process, the heat source is often difficult to control and parts cannot be deformed efficiently. In this study, a numerical model is developed to study the triangle heating technique with the more controllable heat source of high frequency induction heating and to analyze the deformation of steel plate in the heating process. To simplify the many complex trajectories of the triangle heating technique, a rotational path of inductor is suggested and then a 2-dimensional circular heat input model is proposed. The heat flow and transverse shrinkage in steel plate during triangle heating with the induction heat are analyzed. The results of the analyses are compared with those of experiments to show the good
agreement. The heat source and thermo-mechanical analysis models proposed in this study were effective and efficient for simulating the triangle heating technique in the forming of steel plate in shipbuilding.

Technology of Induction Forming Steel Plate

Induction Brazing Steel Tips

Induction Brazing Steel Tips with Hihg Frequency Heating System

Objective To heat a steel tip and shank assembly to 1300°F (704°C) within 3 seconds for brazing with induction heating instead of torch brazing.
Material 0.1” (2.54mm) diameter steel tip & shank, 0.07” (1.78mm) diameter braze ring
Temperature 1300°F (704°C)
Frequency 800kHz
Equipment DW-UHF-4.5kW induction heating system, remote heat station containing one 1.2 microfarad capacitor.
Process A two turn helical coil is used to braze the dental parts. The braze ring is placed at the joint area of the steel tip and shank. Black flux is applied to the joint area. RF power is applied for 3 seconds to heat the parts to the established target temperature and the braze paste flows evenly and consistantly.
Results/Benefits Induction heating provides:
• Fast, accurate, repeatable heat
• Ability to heat very small areas within precise production tolerances
• Better joint quality, reduced oxidation
• Increased production rates and reduced labor costs

Induction Brazing Steel Wire

Induction Brazing Steel Wire With High Frequency Heating Brazer

Objective To heat a coil and a wire assembly to 1300°F (704°C) within 60 seconds for brazing.
Material Platinum coil, steel wire, braze paste
Temperature 1300°F (704°C)
Frequency 1000kHz
Equipment DW-UHF-4.5kW output, remote heat station containing one 1.2 microfarad capacitor, a specially-designed induction coil, an optical pyrometer, stainless steel susceptor, and zirconia
felt to house the susceptor.
Process A C-shaped steel susceptor is used to ensure even heating and for ease of loading and unloading the samples. RF power from the power supply heats the susceptor to the required temperature of 1700°F (926°C) in 45 seconds. After braze paste is applied to the wire assembly, the assembly is placed
inside the susceptor. It takes 3.5 seconds to heat the wire to the optimum brazing temperature of 1300°F (704°C) and the braze paste flows evenly and consistently.
Results/Benefits Induction heating provides:
• Fast, accurate, repeatable heat
• Ability to heat very small areas within precise production tolerances
• Better joint quality, reduced oxidation

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

Induction Brazing Brass Faucet

Induction Brazing Brass Faucet

Objective Brazing two joints on a brass bathroom faucet assembly
Material Brass bathroom fittings 1” OD, brazing rings, flux
Temperature 1148 ºF (620 ºC)
Frequency 90 kHz
Equipment • DW-UHF-30 kW induction heating system, equipped with a remote workhead containing eight 1.0 μF capacitors for a total of 8.0 μF
• An induction heating coil designed and developed specifically for this application.
Process A two turn C shaped coil is used to braze the faucet assembly.
The braze rings are placed at the joint, the parts assembled and fluxed. The first braze joint is heated for 30 seconds and the braze ring flows. The assembly is rotated & the second joint is heated for 30 seconds to flow the braze ring. The two brazes are completed in 60 seconds.
Results/Benefits Induction heating provides:
• Faster, repeatable and consistent results
• Localized heat produces neat and clean joints
• Hands-free heating that involves no operator skill for manufacturing
• Even distribution of heating

Induction Brazing Steel To Carbide Plate

Induction Brazing Steel To Carbide Plate

Objective Brazing a steel piston valve assembly
Material Steel piston valve 4.5” dia (11.43cm), tungsten carbide plate and braze
Temperature 1350 ºF
Frequency 100 kHz
Equipment •DW-UHF-40kW induction heating system, equipped with a remote workhead containing six 1.0μF capacitors for a total of 1.5μF
• An induction heating coil designed and developed specifically for this application.
Process A five turn pancake coil is used to braze the piston valve and tungsten carbide plate. The assembly was heated for 10 minutes to flow the braze and join the two pieces.
Results/Benefits Induction heating provides:
• Rapid localized heat, which can minimize oxidation and reduce cleaning after joining
• Hands-free heating that involves no operator skill for manufacturing
• Clean and controllable joints
• Produces high quality repeatable parts

Hydrogen Atmosphere Brazing Tube To Copper With Induction

Hydrogen Atmosphere Brazing Tube To Copper with induction

Objective: Braze a NI-SPAN-C alloy tube to a steel cap in a hydrogen atmosphere
Material NI-SPAN-C alloy tube (5mm) dia, steel cap (7mm) dia, (7mm) long, nickel braze, quartz tube and hydrogen
Temperature: 1875 ºF (1024 ºC)
Frequency: 350 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 single turn helical coil is used to heat the tube assembly directly. The tube assembly is held in place inside the quartz tube by a copper fixture and hydrogen is fed into the quartz tube. Braze preforms are placed at the braze area and heat is applied for 60 seconds to flow the braze.
Results/Benefits Induction heating provides:
• Rapid localized heat to joint area only
• Minimized oxidation reduces cleaning time
• Improved part quality
• Hands-free heating that involves no operator skill for manufacturing

Brazing Carbide Tips To Steel With Induction

Brazing Carbide Tips To Steel With Induction Heater

Objective: Braze a carbide tip to a 4140 steel cutting tool
Material: Carbide Isograde C2 & C5 tips, 4140 circular steel cutter, flux and silver braze shim
Temperature 1400 ºF (760 ºC)
Frequency 250 kHz
Equipment • DW-UHF-20 kW 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 split helical coil is used to heat the carbide & circular steel cutter evenly for the brazing application. The circular steel cutter is placed in a vise and the carbide and braze shim are placed onto the tooth. The assembly is heated for 5 seconds to braze the carbide to the circular steel cutter. The circular steel cutter is rotated in the vise & each carbide tip is brazed separately without effecting the previous braze.
Results/Benefits Induction heating provides:
• Rapid, localized heat applied only to tip being brazed, will not effect previous brazes on the assembly
• Neat and clean joints
• Produces high quality repeatable parts

Brazing Wire to Copper Bar With Induction

Brazing Wire to Copper Bar With Induction

Objective: To heat a compacted litz wire bundle for wire stripping then braze the litz wire bundle to a copper block for use in an automotive motor.
Material: Compacted litz wire bundle 0.388” (9.85mm) wide, 0.08” (2.03mm) thick copper bar 0.5” (12.7mm) wide, 0.125” (3.17mm) thick and 1.5” (38.1mm) long braze wire & white flux
Temperature 1400 ºF (760 ºC)
Frequency 300 kHz
Equipment • DW-UHF-10 kW 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 three turn helical coil is used for the wire stripping process.The litz wire bundle is placed in the coil for 3 seconds to strip the lacquer 0.75” (19mm) from the end of the bundle. The wire bundle is then scraped with a metal brush to remove the burnt lacquer. For the brazing process a two turn channel coil is used. The litz wire and copper assembly are placed in the coil and the braze wire is fed by hand. The braze is completed in 45-60 seconds.
Results/Benefits Induction heating provides:
• Consistent, repeatable results
• Faster process time, increased production
• Even distribution of heating

Brazing Silver To Copper With Induction

Brazing Silver To Copper With Induction

Objective: Heat silver contacts and brass/copper bus for brazing application
Material: Silver contact .75 (19mm) diameter, brass and copper bus 2” x 1” (50.8 x 25.4mm), braze shims, white flux
Temperature 1300 ºF (704 ºC)
Frequency 300 kHz
Equipment • DW-UHF-10kW induction heating system, equipped with a remote workhead containing two 1.0μF capacitors for a total of 0.5 μF
• An induction heating coil designed and developed specifically for this application.
Process A five turn split helical coil is used to heat the assembly. The parts are placed 90º to the coil between the top turn and second turn with braze shims and flux. The parts reach 1300ºF (704 ºC) in less than 40 seconds to braze the parts together.
Results/Benefits Induction heating provides:
• Hands-free heating that involves no operator skill for manufacturing
• Better joint quality
• Faster heating cycles, more consistent results
• Even distribution of heating