induction preheating copper rod

high frequency induction preheating copper rod and connector for an epoxy curing application

induction preheating copper rod and connector for an epoxy curing application Objective: To preheat a portion of the copper rod and a rectangular connector to temperature prior to epoxy curing during a manufacturing process for electrical turnbuckles Material : Customer supplied plated copper rod (12” x 2” x 1”/305mm x 51mm x 102 mm) and connector Temperature :302 ºF (150 ºC) Frequency :25 kHz Induction Heating Equipment: -DW-HF-60kW 15-45 kHz induction heating system equipped with a remote workhead containing four 21 μF capacitors - A single position seven-turn helical induction heating coil designed and developed specifically for this application Induction Heating Process The copper rod and connector were placed inside the induction heating coil and the power was turned on. The part heated to temperature within 55 seconds. After being heated to temperature, the part was moved and an epoxy curing/molding process took place. The client was using a large oven to preheat these rods, which was cost inefficient. Induction offers a faster and more costefficient heating method. Results/Benefits - Speed: Induction heated the part to temperature quickly - Efficiency: Induction is a far more efficient method of heating these parts to temperature when compared to their large oven - Precision: Induction made it possible to heat only the parts of the rod that required heating

Ultrasonic Welding Machine | Ultrasonic plastic Welder For Welding Solution

Ultrasonic welding plastic machine | ultrasonic welder | ultra sonic plastic welding device with Automatic Frequency Chasing

 ♦Fully automatic frequency chasing, suitable for various sizes of welding die and different design mold, automatic chasing frequency range:±400HZ Example: 15KHZ ultrasonic, mold frequency in 14.4-15.2KHZ can Automatic frequency traceability ♦The use of CPU computer to monitor various programs is fast and adaptable. The built-in protection system "system protection monitoring" function will respond to the following situations: the temperature is too high and the pressure is too high, which leads to overload. Excessive current of ultrasonic generator, loosening of solder head, transducer or transducer, failure of generator circuit, etc. ♦Automatic tuning enables the ultrasonic generator to automatically track and compensate for changes in welding head frequency. When the temperature is too high, wear on the surface of the welding head or debris on the head, this frequency change will occur. ♦Built-in automatic constant amplitude system. The ultrasonic amplitude can be adjusted from 50% to 100% stepless to adapt to different welding work. ♦With IGBT, the reaction speed is 100 times faster than that of traditional silica gel power tube.

Model	1520A	1526A	1532A	1542A
Frequency	15KHz
Power	2000W	2600W	3200W	4200W
Voltage	220V
Capacity	10-20 times/min
Driving form	Pneumatic
Stroke Length(Horn Journy)	75mm		100mm
Output Time	0.01-9.99S Adjustable
Welding Area	Φ100	Φ200	Φ300	Φ400
Electricity	AC
Control mode	Numerical control
Working air pressure	1-7 Bar
Weight	90KG	90KG	90KG	120KG
Dimensions	450*750*1100mm			760*1000*1950mm

Main Features 1. Ultrasonic Welding Plastic Machine, manually tuning, simple to use and maintenance. 2. Welding by time, delay time, weld time and hold time. Working pressure is adjustable. 4. Precise and high quality imported pneumatic parts 5. High quality transducer and booster. 6. Self-protection: Over-Current, Frequency Deviation, Over-Temperature 7. Available in 4 frequencies – 15 KHz, 20 KHz ,35 KHz and 40 KHz. 8. Quick application changeover, high welding seam strength. 9. Suitable for high cadences and short cycle times. Applications: Ultrasonic welding plastic machine is widely used in automotive industry, electronic industry, medical industry, household appliances, woven apparel, office supplies, packaging industry, toy industry, and so on. Automotive industry: plastic body parts, car doors, automotive dashboard, lights, mirrors, sun visor, interior parts, filters, reflective material, reflective spike, bumper, cable, plastic filter for motorcycle , Radiator, brake fluid tank, oil cups, water tanks, fuel tank, air hose, exhaust purifiers, the tray plate, and so on. Plastic Electronics: prepaid water meters, communications equipment, cordless phones, mobile phone accessories, cell phone case, battery case, charger, maintenance valve regulated lead-acid batteries, 3-inch floppy disk, U disk, SD card, CF card, USB connection, Bluetooth devices, and so on. Stationery: folder, album, folding boxes, PP hollow board, pen loops, ink cartridges, toner cartridges, and so on. Medical and Daily products: watches, kitchen utensils, oral liquid bottle caps, drip caps, mobile phone accessories, golden soft brush, and daily necessities, handle, security caps, cosmetics bottle, coffee pot, washing machines, air dehumidifiers, Electric irons, electric kettles, vacuum cleaners, speakers, cover and metal face grille and other civil engineering and so on. Health products: children's products, air mattresses, clothes hangers, gardening supplies, kitchenware sanitary ware, shower, shower head, and so on. [wpforms id="3947"]

Induction straightening deck and bulkhead heating solutions

Induction straightening deck and bulkhead heating solutions times by as much as 80 per cent compared to alternative methods. Induction straightening is better at preserving metallurgical properties. It’s also the safest, healthiest, most environmentally friendly straightening method available. The traditional method used for this application is flame straightening. For this, a skilled operator is dedicated to provide heat in specific areas, following a heating pattern, which determines the reduction of distortion in the metal structure. Currently this straightening process has high costs because it requires a large amount of skilled labour, high workplace hazards, contamination of work area and high energy consumption. During the welding of plates to fixed structures, buckling stress is produced. In order to eliminate this distortion, different traditional deck and bulkhead straightening techniques are employed: welding of beads in non-visible areas, cutting and re-welding of plates, and stress relieving using flame heating. These techniques are big time consumers, costly and do not provide any added value. Improving the efficiency of this process is paramount. The HLQ Induction Straightening Solution provides a simple, flexible, low-maintenance alternative to traditional deck and bulkhead straightening techniques. The quick, clean induction heating system rapidly generates heat with precision to relief the stress and straighten the plate. Induction Portable Heating Design The HLQ induction straightening heating System is housed in an all-in-one, portable container. The container is placed at a suppport beam; eyebolts are provided for easy movement. Horizontal or Vertical Orientation With just a tool change, the equipment can be used in either horizontal or vertical position. The system can be placed on both flat and tilted surfaces. Low Maintenance The HLQ induction straightening heating System is designed for marine environments and meets both IP55 and AISI1316 requirements. The cabinet is made of stainless steel and the induction process requires no expendable materials. Easy to Operate System operators can master the three basic steps with just a few hours of training.

• Program selection based on plate thickness. The system handles steel plates with thickness of 4 to 20mm, and aluminum plates with thickness of 3 to 6 mm.
• Position the inductor on the heating tool, in horizontal or vertical orientation, at the desired location
• Press the start buttom to begin the program. The advanced induction technology generates the required amount of heat rapidly, without exceeding the Curie temperature.

What is induction straightening?

Induction straightening uses a coil to generate localized heat in pre-defined heating zones. As these zones cool, they contract, "pulling" the metal into a flatter condition.

Where is it used?

Induction heating is widely used to straighten ship decks and bulkheads. In the construction industry it straightens beams. Induction straightening is increas-ingly used in the manufacture and repair of locomotives, rolling stock and heavy goods vehicles.

What are the benefits?

Induction straightening is extremely fast. When straightening ship decks and bulkheads, our customers often report minimum 50% time savings compared to traditional methods. Without induction, straightening on a large vessel can easily consume tens of thousands of man-hours. The precision of induction also boosts productivity. For example, when straightening truck chassis, there is no need to remove heat-sensitive components. Induction is so precise it leaves adjacent materials unaffected.

Induction straightening heating advantages

The replacement of flame straightening by the method of induction has the following advantages:

• Significant time reduction in the straightening operation
• Repeatability and heating quality
• Improved quality of working environment (no hazardous fumes)
• Improved safety for workers
• Energy and labor cost savings

Related industries are shipbuilding, railway and steel structures in construction among others.

   

brazing copper plates overlay joints

Objective The objective of the application test is to braze copper and brass plates overlay joints with induction to replace torch operation. Overylay joints may be brass to brass or copper to copper. The current torch process results in excessive contaminants on the assembly and requires extensive rework after the brazing operation.

Equipment DW-HF-25kw induction heating machine   Materials • Copper and brass coupon plates • Braze alloy – EZ Flo 45

Key Parameters – Copper plates Power: 15 kW Heat to Temp: Approximately 1350° F (732° C) Time: Average time – 2 minutes Process and Results:

1. EZ Flo 45 braze wire was cut into 2” (50.8mm) lengths and placed in the interface area.
2. The assemblies were set up (see photos) and heated with induction heating for an average time of 2 minutes to flow the alloy and achieve the braze.

Key Parameters –Copper Brass coupon plates Power: 15 kW Heat to temp: Approximately 1350° F (732° C) Time: Average time – 2 minutes Process and Results:

1. EZ Flo 45 braze wire was cut into 2” (50.8mm) lengths and placed in the interface area.
2. The assemblies were set up (see photos) and heated for an average time of 2 minutes to flow the alloy and achieve the induction brazing.

Induction Heating Valve Head

Induction Heating Valve Head For Stress Testing With Induction Heating Equipment Objective To heat the face of an engine valve head to 900°F and maintain the temperature for an extended time, high temperature stress test. Material Engine valve head (two sizes), temperature sensing paint Temperature 900 °F Frequency200 kHz for large part; 271 kHz for smaller part Equipment DW-UHF-10KW Induction Heating power supply, remote heat station with one 0.66 mF capacitor, a specially designed, multiturn induction coil and an optical pyrometer. Process A specially designed multi-turn pancake coil was used to provide uniform heat to the part. To provide optimum coupling, the face of the valve head was placed approximately 3/8” away from the coil. RF induction power was applied for 4 minutes to heat the larger valve to 900°F; the smaller valve head required 2 minutes to reach the same temperature. For closed-loop temperature control, the optical pyrometer was then used to maintain the temperature at 900°F. Results Uniform and repeatable results were obtained with the DAWEI power supply and induction coil at 900°F. Depending on the part size, the correct temperature was reached in 2 to 4 minutes.

brazing carbide tips

Objective Induction brazing carbide tips onto milling cutter tools process

Equipment DW-UHF-20kw induction brazing machine Power: 11,5kW (max) Time: 10 sec (to brazing temperature)

Process Steps 1. Induction Heating to brazing temperature to remove stale tool 2. Removing old solder during heating 3. Braze new tool Results and Conclusions: 1. The delivered power to the load was more than enough and the test was performed successful 2. Coil bar connection between customer induction coil and our heat station was only for test purposes 3. Using of foot-switch for this application is useful for this application Conclusions: The induction heating machine performance exceeds customer expectations. The customer was very happy to reduce the time needed for worn carbide tips replacement.

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Induction Brazing Basics

Induction Brazing Basics for jointing copper,silver,brazing,steel and stainless steel,etc. Induction Brazing uses heat and filler metal to join metals. Once melted, the filler flows between close-fitting base metals (the pieces being joined) by capillary action. The molten filler interacts with a thin layer of the base metal to form a strong, leak-proof joint. Different heat sources can be used for brazing: induction and resistance heaters, ovens, furnaces, torches, etc. There are three common brazing methods: capillary, notch and moulding. Induction brazing is concerned solely with the first of these. Having the correct gap between the base metals is crucial. A too-large gap can minimize the capillary force and lead to weak joints and porosity. Thermal expansion means gaps have to be calculated for metals at brazing, not room, temperatures. Optimum spacing is typically 0.05 mm – 0.1 mm. Before you braze Brazing is hassle-free. But some questions should be investigated — and answered — in order to assure successful, cost-effective joining. For instance: How suitable are the base metals for brazing; what’s the best coil design for specific time and quality demands; should the brazing be manual or automatic? At DAWEI Induction we answer these and other key points before suggesting a brazing solution. Focus on flux Base metals must usually be coated with a solvent known as flux before they are brazed. Flux cleans the base metals, prevents new oxidation, and wets the brazing area prior to brazing. It is crucial to apply sufficient flux; too little and the flux may become saturated with oxides and lose its ability to protect the base metals. Flux is not always needed. Phosphorous-bearing filler can be used to braze copper alloys, brass and bronze. Flux-free brazing is also possible with active atmospheres and vacuums, but the brazing must then be performed in a controlled atmosphere chamber. Flux must normally be removed from the part once the metal filler has solidified. Different removal methods are used, the most common being water quenching, pickling and wire brushing.  

brazing heating exchanger

Objective Induction brazing copper pipe of heating exchanger assembly using stationary C coil or U shape induction heating system. Target speed for assembling all 6 joints was 30 seconds, or approximately 5 seconds per joint. The requirement was to braze all of the joints inside the housing without affecting the plastic covers.

Equipment DWS-20 handheld induction brazing machine Materials • Copper tubing • Brazing flux Key Parameters Temperature: Approximately 1292°F (700°C) Power: 15 kW Time: 5 sec per joint

Process: U shape custom coil is suitable for induction brazing of custom samples. Results/Benefits: Prior to induction brazing copper pipe, the customer was using flame brazing and had to braze the joints outside of the enclosure. With the induction brazing, they were able to achieve the following benefits:

• Braze inside the enclosure
• Improve productivity of the brazing operation
• Precise control of the time and temperature
• Safe heating with no open flames
• Higher energy efficiency

Inductioin Shrink Fitting Aluminum Pulley

Inductioin Shrink Fitting Aluminum Pulley With IGBT Heating Units Objective Heat aluminum pulley for insertion of an inner bearing for the automotive industry Material Aluminum pulley 2.3” (60mm) OD x 1.6” (40mm) ID x 1” (27mm) high and inner bearing 0.7” (17.8mm) high x 1.6” (40mm) dia Temperature 464 ºF (240 ºC) Frequency 283 kHz Equipment • DW-UHF-4.5kW 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 three turn helical coil is used to heat the aluminum pulley. The pulley is heated to 464 ºF (240 ºC) in 20 seconds to expand the inner diameter and then the inner bearing is inserted to form the completed part. Results/Benefits Induction heating provides: • Defined and controlled heat pattern • Process easily integrated into automated system • Even distribution of heating  

brazing pipe to pipe end

Objective Induction brazing pipe to pipe end assembly connection. Materials Tube length varies from 39.3″ (1m) to 236.2″ (6 m). Equipment: DW-UHF-10KW induction brazing machine

Key Parameters Temperature: Around 1382°F (750°C) Time: 1 minute to 30 seconds average

Results and Conclusions: The tube end length varies from present 1.57″ to 3.94″ (40mm to 100 mm) and the perforated tube length varies from 3.28ft to 19.685ft (1m to 6 m). The lap Joint length may reach up to maximum 0.28″ (7 mm) in the future. Quality requirements: Lap joint, all holes, joint line at the inside end of lap and joint line on OD of the tubes should get completely suffused with brazing filler. The joint has physical strength requirements also. You will suggest us the final parameters as well as flux and filler metal requirement for proper brazed joint & fixtures, if any.Final tube outer dias will reach upto 1.97″ (50 mm). The length will not differ much.  Perforated tube thickness may reach up to 0.079″ (2 mm) maximum.