Induction Brazing Aluminum Pipes

Induction Brazing Aluminum Pipes Objective: Brazing two aluminum pipes simultaneously to an aluminum evaporator core Material 2 aluminum pipes 0.72" (18.3mm) diameter, evaporator core 9.88" x 10.48" x 1.5" thick (251mm x 266.3mm x 38mm), braze rings Temperature 610 ºF (321 ºC) Frequency 250 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 four turn helical pancake coil is used to heat the 2 pipes simultaneously. Three braze rings are placed on each joint and power is applied for 90-100 seconds to create a leak proof joint on both pipes. Narrative • Customer is requiring a 40 seconds heat time for both brazes. In order to meet this requirement 3 units will be utilized to braze 2 joints each for a total of 6 joints in 90-100 seconds. The customer is currently using a flame process which can burn away the thin flange at the joint area and create scrap parts. By switching to induction for this application the customer is decreasing their scrap parts and also increasing their quality and production rate. Results/Benefits Induction heating provides: • Repeatable leak free joints • Increased part quality, less scrap • Hands-free heating that involves no operator skill for manufacturing • Even distribution of heating https://dw-inductionheater.com/induction-brazing-aluminum-pipes.html?feed_id=252018&_unique_id=668094ca1f03f

Brazing Aluminum to Copper Tubes with Induction

Brazing Aluminum to Copper Tubes with Induction Objective: To heat an aluminum manifold to 1050 ºF (566 ºC) for a brazing application: Material :

• Cu tubes (3/4"/19mm)
• Cu tubes (5/8"/15.8mm)
• AI tubes (3/8"/9.5mm)
• AI manifold (5/8"/15.8mm)
• AI manifold (3/4"/19mm)
• Lucas-Milhaupt Handy One alloy 30-832
• Braze wire

Temperature 1050 ºF (566 ºC) Frequency 260 kHz Equipment DW-UHF-10KW 150-500 kHz induction heating system equipped with a remote heat station containing two 1.5 μF capacitors.

• A two-turn oval helical induction heating coil designed and developed specifically for the aluminum assembly
• A five-turn helical induction heating coil designed and developed specifically for brazing the Cu tubes to AI joint assembly

Process Braze : pre-forms were designed to fit the aluminum tubes. Then the four aluminum tubes were placed into the manifold and the assembly was inserted into the coil. The assembly was heated for approximately 70 seconds, at which point it reached the targeted temperature and braze flowed. For the Cu tubes, a braze pre-form was also designed for them, wound around the tubes, and the assembly was placed inside the coil. The heating cycle time was approximately 100 seconds. Some joints required stick feeding of braze to fill the entire joint area due to the braze wire size. If the cycle time was lengthened, the need for stick feeding would be eliminated. Results/Benefits: Precise, repeatable heating:

• The client wanted more precise and repeatable heating than a torch could deliver, which induction was able to achieve .
• Temperature control: Induction allows for superior temperature control when compared to other methods, including a torch, which the client desired

  https://dw-inductionheater.com/brazing-aluminum-to-copper-tubes-with-induction.html?feed_id=251950&_unique_id=667fdddf0f02e

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

https://dw-inductionheater.com/brazing-aluminum-pipes-assembly-with-induction.html?feed_id=251882&_unique_id=667f2713e0e14

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. https://dw-inductionheater.com/induction-aluminum-brazing-process.html?feed_id=251814&_unique_id=667e70353f5d3

What Is Induction Heating Coil&Inductor?

What is induction heating coil & inductor? The varying magnetic field required for induction heating is developed in the induction heating coil via the flow of AC (alternating current) in the coil. The coil can be made in many shapes and sizes to custom fit a specific application. The coils can range from tiny coils made of copper tubing used for precise heating of extremely small parts in applications such as soldering and ferrule heating to large coil assemblies of copper tubing used in applications such as strip metal heating and pipe heating. What is the importance of the induction heating coil (inductor)? The induction coil design is one of the most important aspects of an induction heating system. The coil is a custom design to give your work piece or part the proper heating pattern, maximize efficiency of the induction heating power supply’s load matching system, and to accomplish these tasks while still permitting ease of loading and unloading your part. https://dw-inductionheater.com/what-is-induction-heating-coil-inductor.html?feed_id=251746&_unique_id=667db9912459d

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. https://dw-inductionheater.com/brazing-carbide-to-steel-with-induction.html?feed_id=251678&_unique_id=667d02fb8f6ce

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 https://dw-inductionheater.com/brazing-brass-to-aluminum-with-induction.html?feed_id=251610&_unique_id=667c4c29db306