Technologies Archives - Page 30 of 37 - Manufacturer of Induction Heating Systems

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

Induction Heating Steel Part For Hot Heading

Induction Heating Steel Part For Hot Heading With IGBT Induction Heater

Objective Heating steel parts to 1900ºF (1038ºC) for hot heading application
Material Steel parts with 7/16” (11.11mm) OD and ceramic piece
Temperature 1900 ºF (1038ºC)
Frequency 440 kHz
Equipment • DW-UHF-6kW induction heating system, equipped with a remote workhead containing one 0.66μF capacitor.
• An induction heating coil, designed and developed specifically for this application.
Process A four turn helical coil with ceramic insert is used to heat a 0.75” (19mm) section of the part to 1900ºF (1038ºC) for 7.5 seconds. A ceramic piece is so the part does not come in
contact with the coil.
Results/Benefits Induction heating provides:
• Hands-free heating that involves no operator skill for manufacturing
• Direct application of the heat on the work piece with precision and consistency
• Even distribution of heating
• Low pressure and minimal residual part stress

Induction Heating Wires For Hot Heading

Induction Heating Wires For Hot Heading With IGBT Induction Heating Units

Objective To heat multiple steel wires to 1350ºF (732ºC) for hot heading application
Material Steel wire 0.185” (4.4mm) OD
Temperature 1350 ºF (732ºC)
Frequency 141 kHz
Equipment • DW-UHF-6 kW induction heating system, equipped with a remote workhead containing one 0.66μF capacitor
• An induction heating coil designed and developed specifically for this application.
Process A two turn channel coil is used to heat 12 wires at a time to reach the required 130 parts per minute. The wires are placed 0.5” (12.7mm) on center. The top 0.3” (7.6mm) of the wires are
heated for 5 seconds to achieve the desired temperature.
Results/Benefits Induction heating provides:
• Hands-free heating that involves no operator skill for manufacturing
• Elimination of springback effect
• Extended die life
• Better grain flow and microstructure
• Even distribution of heating

Induction Preheating Hot Heading

Induction Preheating Hot Heading For Single Rod With IGBT Induction Heater

Objective Heat a waspaloy rod to 1500ºF (815.5ºC) for hot heading application
Material Waspaloy rod 0.5” (12.7mm)OD, 1.5” (38.1mm) length, ceramic liner
Temperature 1500 ºF (815.5ºC)
Frequency 75 kHz
Equipment • DW-HF-45KW induction heating system, equipped with a remote workhead containing two 1.32μF capacitors for a total of .66μF
• An induction heating coil designed and developed specifically for this application.
Process A seven turn helical coil is used to heat the rod. The rod is placed inside the coil and power is applied for two seconds providing enough heat to penetrate the inner core. An optical pyrometer is used for close loop temperature control and a ceramic liner is used so the rod does not touch the coil.
Results/Benefits Induction heating provides:
• Low pressure and minimal residual stress
• Better grain flow and microstructure
• Even distribution of heating
• Improved production rates with minimal defects

Induction Heating Stainless Steel

Induction Heating Stainless Steel Rod For Hot Forming With RF Induction Heating Units

Objective Heating 300 series stainless steel rod to 1800ºF (982ºC) for forming application
Material 1” (25.4mm) length of 300 series stainless steel rod ¾ “ (19mm) diameter
Temperature 1800 ºF (982ºC)
Frequency 52 kHz
Equipment • DW-HF-25kW induction heating system, equipped with a remote workhead containing two 1.25μF capacitors for a total of .625μF
• An induction heating coil designed and developed specifically for this application.
Process A four turn helical coil is used to heat the stainless steel rod to 1800 ºF (982ºC) for 10 seconds. For manufacturing purposes a refractory shield should be used between the coil and rod to
keep the heat directed on the rod. Refractory shield was not used during testing.
Results/Benefits Induction heating provides:
• Hands-free heating that involves no operator skill for manufacturing
• Improved production rates with minimal defects
• Low pressure and minimal residual part stress
• Even distribution of heating

Induction Heating Aluminum Pipe

Induction Heating Aluminum Pipe For End Forming With High Frequency Induction Heater

Objective Through heating the top 2” (50.8mm) of aluminum oxygen tank to form a rounded end with a hole for oxygen valve
Material Aluminum oxygen tank with open end 2.25” (57.15mm) diameter, 0.188” (4.8mm) wall thickness
Temperature 700 ºF (371 ºC)
Frequency 71 kHz
Equipment • DW-HF-45kW 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 five turn helical coil is used to heat the open end of the oxygen tank. The tank is heated for 24 seconds to reach 700ºF (371 ºC).
Results/Benefits Induction heating provides:
• Uniform through heating
• Fast, energy-efficient heat
• Fast, controllable and repeatable process
• Hands-free heating that involves no operator skill for manufacturing

Induction Heating Steel Pin

Induction Heating Steel Pin For Loosening With RF Induction Heater

Objective Heat steel tie downs on containers to loosen steel pin so pin can rotate
Material Steel tie-down assembly with a 2.5” (63.5mm) dia. flange, 1” (25.4mm) dia. rod and pin ring approx 4” (101.6mm) OD and 0.75” (19.05) thick steel
Temperature 1000ºF (538ºC)
Frequency 282 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 assembly. The coil is placed around the pin and power is applied for 120 seconds. After heating, a steel rod is inserted in the pin ring, pressure is
applied and the pin ring spins freely.
Results/Benefits Induction heating provides:
• Precise and accurate placement of heat without affecting surrounding areas
• Much faster process time, from hours to minutes
• Repeatable and consistent results
• Even distribution of heating

Induction Hot Plate

High Frequency Induction Hot Plate with a Tin Coating for Flow-Melting

Objective Heat a carbon steel plate coated with tin to 450 ºF (232 ºC) for flow-melting
Material 7.9” (200mm) x 4.7” (120mm) steel plates with a tin layer of 100 to 1000nm thickness, temperature sensing paint, water for quenching
Temperature 450 ºF (232 ºC)
Frequency 350 kHz
Equipment • DW-UHF-20kW induction heating system, equipped with a remote workhead containing two 0.5μF capacitors for a total of 0.25μF
• An induction heating coil designed and developed specifically for this application.
Process A nine turn “Dog Bone” style coil is used for the flow-melting process. The tin coated carbon steel plate is placed in the coil for 1.34 seconds to uniformly reflow the tin coating. The plate is then quenched in cool water to retain sufficient free tin at the surface.
Results/Benefits Induction heating provides:
• Uniform heating
• Rapid focused heat