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Although torch brazing is the most widely used brazing method, it is a difficult task for many manufacturers to find skilled operators for the process. In addition, due to the open flame, it raises the supervision and safety issues of production facilities. Furnace brazing is also a common form of brazing.

Use induction instead of torch brazing in aluminum manifold applications.

Today, manufacturing companies are looking for ways to improve production efficiency, reduce production costs, and replace energy and space-efficient furnaces without affecting product quality. Induction brazing is the answer to the above questions because it does not require skilled operators, reduces equipment footprint, minimizes energy costs, and implements lean production processes for higher quality parts.

The brass mixing nozzle was induction brazed to the dual feed copper tube used for the oxyacetylene torch nozzle assembly. 6 kW at 380 kHz for 36 seconds to 732°C (1350°F).

Induction brazing is used to join various metals, including copper and aluminum, aluminum and aluminum, copper and copper, brass and copper, brass and copper, steel-to-copper, steel-to-brass, and steel-to-steel.

Steel-to-steel brazing of regulator components used in the petroleum industry. 200kHz for 9 seconds at 8kW to 732°C (1350°F).

The steps for high-quality induction brazed joints include:

Tensile strength with joint gap

The best brazed joint strength appears in the part joint gap between 25μm (0.001") and 125μm (0.005"). Data comes from Lucas Milhaupt.

Brazing filler materials are used to provide metallurgical bonding on the material surfaces on both sides of the joint. Typical brazing filler materials used to form the alloys required for the joint material include aluminum, nickel, zinc, silver, and copper. Some filler alloys exhibit eutectic properties and support the brazing process by allowing the alloy to melt and flow at a temperature lower than the melting temperature of the base material, as shown in Figure 5.

The flux is used to protect the two metal surfaces to be connected and the brazing material from being oxidized during the heating process. Some flux materials can also be used as cleaning agents. Potassium salts of fluorine and boron with a temperature range of 565–982 °C are typical flux materials for low temperature brazing. Flux materials with less fluorine are used for higher brazing temperatures of 870–1100 °C.

The operating temperature range of fillers and fluxes for brazing typical materials of steel, copper, brass and aluminum.

The advantages of induction brazing technology include:

Using induction to heat aluminum requires a lot of energy, because aluminum has a thermal conductivity of 60% compared to copper. The time of heat flow and coil design are critical to the use of induction brazed aluminum parts. Due to recent developments in low-temperature aluminum brazing materials, flame and furnace heating have been successfully replaced by induction in the large-volume brazing of aluminum components. Ambrell provides solutions for precision aluminum brazing applications.

The aluminum cable joint is brazed to the aluminum tube for use in making bicycles. 20kW at 10kHz for 45 seconds to 482°C (900°F) using rod brazing. Braze two parts simultaneously in the coils in two positions.

Induction brazing is a suitable process for joining steel parts that cannot be welded. Well-designed induction brazed steel joints have several advantages, including lower part stress and part geometric integrity.

Carbon steel and stainless steel are induction compatible, easy to heat, and have high resistivity. Nevertheless, due to their poor thermal conductivity, induction brazing of steel parts must be carried out at a slow speed. For steel, it takes time for heat to pass through the joint surface to wet the brazing material and allow it to flow normally. Nickel-based alloys are commonly used as stainless steel, while copper-based alloys are used as low-cost brazing materials on carbon steel. Ambrell's induction brazing experts have the experience to provide the required solutions for joining different parts. The following table lists the thermal conductivity, resistivity and typical melting temperature of different materials.

Induction brazing is an ideal process for joining dissimilar metal parts. Applications for mixed metal connections include brass-to-copper, steel-to-brass, and steel-to-copper.

The torch brazing on the copper elbow is replaced with a copper tube using a split spiral coil. 7kW at 190kHz for 90 seconds to 760°C (1400°F).

For brazing of different metals, the two metal surfaces must reach the brazing flow temperature at the same time as the joint. Induction heating solutions must consider the different thermal conductivity of the material and the time it takes for the material to reach the desired temperature.

Using multi-position spiral coils instead of torch brazing, two or three nickel-plated steel ferrules are induction brazed to the nickel-plated pins of automobile bulbs. 8kW at 360kHz for 6 seconds to 620°C (1150°F).

Replace the torch brazing of the two brass joints on the faucet manifold. Each joint is induction brazed using saddle coils. 22kW at 90kHz for 30 seconds to 620°C (1150°F).

The steel tube assembly was induction brazed at 3.5 kW at 220 kHz to 732°C for 30 seconds. Ambrell's EASYHEAT 3.5kW power supply is used for brazing various tube components.

When assembling the air conditioning manifold, a two-step induction brazing process is used instead of torch brazing. The first step is to braze four aluminum tubes into the aluminum manifold using a slender coil for 60 seconds, reaching 566 °C at 3.5 kW and 180 kHz. Then provide 3 kW of power for 95 seconds of copper-aluminum brazing at a frequency of 200 kHz.

The copper elbow can be induction brazed on a flexible stainless steel pipe with a diameter of 102 mm by heating the surface to 675 °C and using a 10 kW power supply at a frequency of 128 kHz for 3 minutes. Stainless steel pipes are used to enable pipes in large buildings to withstand movement in the structure.

Using a saddle coil, the two stainless steel ends of the medical tool shown in the figure below can be brazed to the stainless steel flange using a single induction brazing process and used at 3 kW and 180 kHz in 20 seconds.

EASYHEAT 1.2 and 2.4kW are used for brazing small parts, while EASYHEAT 4.2, 6, 9 and 10kW are used for various brazing applications involving small or thin-walled parts or brazing multiple parts at the same time.

EKOHEAT 10 and 15kW are used for different brazing applications involving more quality parts, while EKOHEAT 30 and 45 and 50kW are used for brazing applications that require faster heating times and involve the brazing of larger parts.

Ambrell offers versatile systems with multiple capacitor and tapped transformer configurations. These systems can braze small or large parts or multiple metal materials with optimal productivity and cost efficiency.

This information is derived from materials provided by Ambrell Induction Heating Solutions and has been reviewed and adapted.

For more information on this source, please visit Ambrell Induction Heating Solutions.

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