Technologies

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

Brazing Stainless Steel To Copper With Induction

Brazing Stainless Steel To Copper With Induction  Heater

Objective Braze a stainless steel braided hose to copper elbows for a braided hose assembly.
Material Stainless steel braided hose 3/8” (9.5mm) OD, copper elbow 1/4” (6.3mm) OD, braze preform rings and black flux
Temperature 1400 ºF (760 ºC)
Frequency 300 kHz
Equipment • DW-UHF-6kW-III 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: A two turn helical coil is used to heat the braided hose assembly. Braze rings are placed at the joint on the copper elbow and flux is applied to the entire surface of the assembly.
The assembly is placed in the heating coil and the braze flows within 30-45 seconds. This creates a liquid and gas tight braze between the copper and stainless steel braided hose.
Results/Benefits Induction heating provides:
• Liquid and gas-tight braze
• Energy efficient heat in a minimal amount of time
• Controllable braze flow through the use of braze rings
• Even distribution of heating

Induction Brazing Stainless Steel

Induction Brazing Stainless Steel Car grill 

Objective Braze an end plug on a stainless steel car grill before powder coating application
Material Stainless steel car grill 0.5” x 0.19” (12.7mm x 4.8mm), end plugs and braze ring
Temperature: 1350 ºF (732°C)
Frequency:400 kHz
Equipment •DW-UHF-6kW-III 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 three turn square shaped helical coil is used to heat the end of the grill. End plugs are inserted into the grill and the assembly is inserted into the coil for 30 seconds. The braze flows to create a neat and clean leak-proof joint.
Results/Benefits Induction heating provides:
• Rapid localized heat to joint area only
• Minimized oxidation reduces cleaning time
• Hands-free heating that involves no operator skill for manufacturing
• Even distribution of heating

Brazing Joining Copper Connectors With Induction

Brazing Joining Copper Connectors With Induction

Objective: Brazing a joint between a copper lug and nickel plated copper pins on a pressurized heater connector.
Material: 1.5” (38.1mm) dia heater connector in a ceramic insulator with L shaped copper lugs and nickel plated copper pins, silver solder and braze
Temperature 1175-1375 ºF (635-746 ºC)
Frequency 270 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 two turn helical coil is used to heat the copper lugs and nickel plated copper pins for 1 minute. A clamp is used in production to hold the copper lugs in place for brazing.

Results/Benefits Induction heating provides:
• Minimal transfer of heat to adjacent ceramic insulator.
• Hands-free heating that involves minimal operator skill for manufacturing.
• Flameless processing.
• Heat very small precise areas within production tolerances.
• Even distribution of heating.

Brazing Golf Ball With Induction

Brazing Golf Ball With Induction

Objective: Heating steel golf ball mold to brazing dimple insert
Material: Golf ball mold 2” in diameter, braze flux paste, dimple insert
Temperature: 1400 ºF (760 ºC)
Frequency: 260 kHz
Equipment • DW-UHF-10kW induction heating system, equipped with a remote workhead containing two 0.5μF capacitors for a total of 0.25 μF
• An induction heating coil designed and developed specifically for this application.
Process A four turn helical coil is used to heat the golf ball mold to 1400ºF (760 ºC) in 3 minutes and the dimple insert is brazed to the mold with braze flux paste.
Results/Benefits Induction heating provides:
• No flame process.
• Reliable, repeatable, non contact and energy efficient heat in minimal time.
• Even distribution of heating.

Induction Brazing Aluminum Automotive

Induction Brazing Aluminum Automotive 

Objective: Heat aluminum for an automotive brazing application
Material: Aluminum tubing 0.50 (12.7mm) dia, an aluminum boss 1” (25.4mm) long, flux filled braze rings
Temperature: 1200 ºF (649 ºC)
Frequency: 370 kHz
Equipment • DW-UHF-10KW induction heating system, equipped with a remote workhead containing one 1.0μF capacitors for a total of 1.0 μF
• An induction heating coil designed and developed specifically for this application.
Process A multi turn pancake coil is used to heat the joint between the aluminum tubing and boss. The joint heats to temperature in 1.5 minutes and the braze ring melts forming a clean brazed
joint.
Results/Benefits Induction heating provides:
• Hands-free heating that involves minimal operator skill for manufacturing
• Flameless application
• Reliable, repeatable aesthetically pleasing braze joint
• Even distribution of heating

Brazing Automotive Parts With Induction

Brazing Automotive Parts With Induction

Objective: To braze a automotive steel tube to a steel “T” fitting
Material 1” (25.4mm) diameter steel tubing, steel fitting, braze slug and black flux
Temperature 1400ºF (760ºC)
Frequency 200 kHz
Equipment • DW-UHF-10 kW 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 four turn split helical coil is used to heat the steel assembly to 1400ºF (760ºC) for 85 seconds. The coil design allows for the steel fitting to expand away from the steel tube which allows braze to flow through the joint. The amount of braze alloy is controlled by the braze slug allowing for an aesthetically pleasing joint.
Results/Benefits Induction heating provides:
• Hands-free heating that involves no operator skill for manufacturing
• Precise and uniform distribution of heating
• The collection of flux on the coil is reduced due to efficient coil design.

Brazing Carbide To Steel Shank

Brazing Carbide To Steel Shank with Induction

Objective :Brazing carbide teeth to a steel jaw in less than 5 minutes
Material: Steel pipe jaw, 0.5” (12.7mm) dia, 1.25” (31.75mm) long, 0.25”(6.35mm) thick carbide teeth, black flux and silver copper braze shims
Temperature: 1292ºF (700ºC)
Frequency: 300kHz
Equipment • DW-UHF-10kW 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 rectangular helical coil is used to heat the carbide and steel to 1292ºF (700ºC) for 4 to 5 minutes. Three braze shims control the amount of braze and the even heat allows for
a good flow of braze creating an aesthetically pleasing bond.
Results/Benefits Induction heating provides:
• Hands-free heating that involves no operator skill for manufacturing
• Consistent, repeatable aesthetically pleasing brazes
• Even distribution of heating

Induction Brazing Stainless Steel

Induction Brazing Stainless Steel

Objective
1st Application: Braze hub assembly to needle holder
2nd Application: Braze Large tube to ring joint
Material: 1st Application: Steel hub assembly and needle 0.1″ dia(2.5mm) 2nd Application: Steel tube 1″ OD (25.4 mm) and ring
Temperature 1400 ºF (760 ºC)
Frequency 325 kHz for brazing the needle 0.1″ dia (2.5mm) 259 kHz for brazing ring to steel tube 1″ OD (25.4 mm)
Equipment • DW-UHF-4.5KW induction heating system, equipped with a
remote workhead containing two .66 μF capacitors for a total of 1.32 μF
• Two induction heating coils, designed and developed specifically for this dual application.

Process 1st application: A two-turn helical coil is used to heat the hub assembly on the needle holder for 10 seconds. The coil concentrates the heat on the hub only, as the needle is magnetic and the hub material is non-magnetic. A small
diameter braze wire is used to supply sufficient amount of braze creating a strong aesthetically pleasing bond. 2nd application: A three-turn helical coil is used for brazing the large tube to the ring joint for 3-5 minutes. A braze ring is
used to supply sufficient amount of braze to create an aesthetically pleasing bond.

Results/Benefits Induction heating provides:
• Even distribution of heating, provides even flow of braze alloy for an aesthetically pleasing bond
• System flexibility allows for the same unit to be used for two different applications which is a cost saving.

Brazing Copper Bars with Induction

Brazing Copper Bars with Induction

Objective: To braze bus bar assemblies together
Material: • 2 copper bus bars 6″ (152.4mm) wide, 2′ (609.6mm)long, 2
copper bars 6″(152.4mm) wide, 18″ (457.2)long & 3/8″ (9.65mm) thick • braze shim preforms and white flux
Temperature: 1292 ºF (700 ºC)
Frequency: 80 kHz
Equipment • DW-UHF-60KW induction heating system, equipped with a
remote workhead containing eight 1.0 μF capacitors for a total of 2.0 μF.
• An induction heating coil, designed and developed specifically for this application

Process: A three-turn helical coil is used to heat the assembly. Three braze shim preforms are placed between the plates and white flux is applied to the assembly. It is heated for 5 minutes to evenly flow the braze alloy. A high current capable, aesthetic looking braze zone is produced.

Results/Benefits Induction heating provides:
• Consistently produced, quality parts
• Heat into the part that is divided equally between the copper pieces, allowing for even flow and consistent use of braze
• Hands-free operation that doesn’t require skilled operators

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