Technologies Archives - Page 34 of 36 - induction heating machine manufacturer

Brazing Steel To Steel Pipe With Induction

Brazing Steel To Steel Pipe With Induction

Objective: To braze O-ring Face (ORFS) sleeve or male connector to a steel tube.

Material

• Steel tube, 1 inch (2.54 cm) OD

• O-ring Face Seal sleeve and a male connector fittings

• Preform braze rings

• White SureFlow flux

• Steel support mandrel

Temperature 1300 ºF (704 ºC)

Frequency 200 kHz

Equipment

• DW-UHF-20KW induction heating system, equipped with a remote workhead containing two (2) 1.5 μF capacitors (for a total of 0.75 μF).

• An induction heating coil designed and developed specifically for this application.

Process A four-turn 2.75 inch (7.0 cm) ID helical coil is used for heating both the steel tube and the ORFS sleeve or the ORFS male connector. This coil is designed to braze either the sleeve or male connector to the tube. The parts to be brazed are assembled with flux and heated for 45 seconds. Pressure is applied to the tube to make sure it is inserted fully into the fittings as the braze ring flows.

Results/Benefits Advantages :

• Large Inner diameter of coil allows for easy loading and unloading of parts

• With efficient energy coupling of the coil to the fittings overheating is avoided.

Brazing Carbide-Steel Tool with Induction

Brazing Carbide-Steel Tool with Induction

Objective: Provide a solution to this steel-carbide brazing application Material • Body 10mm; carbide tip 57 x 35 x 3 mm • Braze shim • Braze flux white

Temperature: 750°C (1382ºF)

Frequency: 150 kHz

Equipment DW-UHF-20KW induction heating system, equipped with a remote heat station containing (2) 1.0 μF capacitors (for a total of 0.5 μF) A 4.5″ helical induction heating coil designed and developed specifically for this application.

Process: The body shim and carbide are cleaned and braze flux as applied to the entire surface of the assembly. The parts are placed together in the induction coil. Two ceramic tubes are then placed thru the coil opposing each other to hold the parts during heating. The flux on the parts is allowed to dry before heating. The induction heating power is applied until the braze flows in the joint.

Results/Benefits

• targeted heating of the braze joint is efficient

• flameless process is more precise, controllable

• results are reproducible

Brazing Brass Pipe With Induction

Brazing Brass Pipe With Induction

Objective: Block is heated to 1400°F to braze trap tube to assembly

Material :brass block and pre-formed tubes braze pre-forms

Temperature: 1400 ºF (760°C)

Frequency: 350 kHz

Equipment DW-UHF-10KW induction heating system including • Coil: custom-designed 2-turn split-helical • Workhead: contains two 1.0μF capacitors (0.5 μF total)

Process The brass parts, braze pre-form and flux are assembled and located within the custom-designed coil. Induction heating of the joint is accomplished in 45 seconds.

Results/Benefits

Economy: induction heats only the material within the coil; no energy is wasted heating the surrounding materials and air; no flame or gasses required for heating Control: process lends itself to the use of braze pre-forms; process easily adapted to automation

Efficiency: energy is expended only during the joint formation

Brazing Copper to Brass Pipe With Induction

Brazing Copper to Brass Pipe With Induction

Objective: Brazing several brass and copper assemblies used in water faucets Material braze, white flux

Temperature 1350 °F 730°C

Frequency 200 or 280 kHz (coil dependant)

Equipment DW-UHF-10KW induction heating system, remote work head with two 1μF capacitors and a 3-turn helical coil

Process: Three helical coils are used separately to braze a range of provided parts. Parts are assembled with flux and a braze alloy and then heated. The heat time varies from part to part with large parts taking less than 3 minutes and, the smaller parts heated in less than 20 seconds. After heating the parts are quench-cooled.

Results/Benefits

Repeatability: the inherent precision of induction heating supports a process which is highly repeatable.

Economy: the process allows for the use of higher temperature braze alloy than a flame process

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

Brazing Carbide Tool Tips With Induction

Brazing Carbide Tool Tips With Induction

Objective: Attaching carbide cutters to a steel meat cutter impeller

Material carbide blocks; steel shank fitting

Temperature 1400 °F (760 °C)

Frequency 300 kHz

Equipment DW-UHF-30KW induction heating systems including: Induction heating coil Workhead: two-cap 1.0μF (Total 0.5 μF) Process The entire part is placed in a five-turn helical coil, the power is applied until the part is heated to the required temperature and a uniform heat pattern is achieved. The coil allows for easy fixturing and uniformity of heating between the carbide and the steel shank for a premium braze joint.

Results/Benefits

Precision: Due to the size of the induction coil, the process allows for precise placement of the carbides on the steel shanks

Economy: Power is consumed only during the heat cycle

Repeatability: joint quality is maintained in this repeatable process

Brazing Brass to Aluminum with Induction

Brazing Brass to Aluminum with Induction

Objective: Copper ‘tees’ and ‘ells’ are to be brazed to the aluminum body of a refrigeration valve

Material customer’s valve copper fittings braze

Temperature 2550 ºF (1400°C)

Frequency 360 kHz

Equipment DW-UHF-10KW induction heating system including a workhead containing two 1.5μF capacitors (total 0.75μF) and a three-turn helical coil

Process The valve is placed inside the coil and RF power is applied until the part is heated to the required temperature and the braze is seen to flow into the joint. Two tube sizes were run using the same induction system settings with differing cycle times.

Results/Benefits • energy is applied only to the zone to be heated • heating of the joint/braze is uniform and repeatable

Brazing Carbide To Steel With Induction

Brazing Carbide To Steel With Induction

Objective: Braze carbide rotary file assemblies with uniform concentricity in an aerospace application

Material :

• Carbide blank

• High speed steel shank

• Temperature indicating paint

• Braze shim and black flux

Temperature 1400°F (760°C)

Frequency 252 kHz

Equipment DW-UHF-10kw induction heating system, equipped with a remote heat station containing two 0.33 μF capacitors (total 0.66 μF) An induction heating coil designed and developed specifically for this application.

Process A multi-turn helical coil is used. The part is heated to determine the time required to reach the desired temperature and required heat pattern. It takes approximately 30 – 45 seconds to reach 1400°F (760°C) depending on the various part sizes. Flux is applied to the entire part. A braze shim is sandwiched between the steel shank and carbide. Induction heating power is applied until the braze flows. With proper fixturing, concentricity of the part can be achieved.

Results/Benefits • Repeatable, consistent precise heat.

Induction Aluminum Brazing Process

Induction Aluminum Brazing Process

Induction aluminum brazing is becoming more and more common in industry. A typical example is brazing various pipes to an automotive heat exchanger body. Aluminum requires a lot of energy to heat using induction and its thermal conductivity is 60% compared to copper. Coil design and time for the heat to flow is critical in a successful induction brazing process for aluminum parts. Recent advances in lower temperature aluminum braze materials have allowed induction to effectively replace flame and furnace heating in high volume brazing of aluminum assemblies.

Successful Induction brazing of aluminum parts requires the correct braze filler material for the aluminum alloy used in the parts and the correct flux for the braze alloy. Braze filler manufacturers have their own proprietary aluminum braze alloys and flux materials that work with their alloys.

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