Brazing stainless steel with induction

High frequency induction brazing stainless steel tube to stainless steel fitting with DW-HF-25kw-A induction heater.

Objective Brazing stainless steel tubing and stainless steel fittings Equipment DW-HF-25kw-A induction brazing machine

Materials 1.75″(44.45mm) Hexagon fitting Power: 10.52 kW Temperature: 1300°F (704°C) Time: 30 seconds

Results and Conclusions:

• Induction heating pinpoints the heat to the desired area of the part
• Improved process control for precise heating to a desired temperature
• Power on demand and rapid, consistent heat cycles
• Technology without pollution, which is both clean and safe

Induction Soldering Stainless Steel Tubes to Brass Base

Objective Induction Soldering stainless steel tubes to brass base Equipment DW-UHF-6KW-III handheld induction heater

Materials Customer material including flux Key Parameters Power: 2 kW Temperature: 482°F (250°C not measured) Time: 14 -16 sec

Process Steps Customer process instruction has been followed DW-UHF-6KW-III induction heating system was limited to 2kW Results and Conclusions Sample position according to the coil is vital.Induction Soldering Stainless steel is heated much fasted than the brass. So, the coil is positioned over the brass part (around 95%)

Electromagnetic Induction Heating Steam Generators

The principle of induction steam boilers|

electromagnetic induction steam generators|induction heating steam boilers

This invention relates to an induction steram boiler|electromagnetic induction steam generator which operates with a low-frequency alternating current electric power source. More specifically, this invention relates to an electromagnetic induction steam boiler which is compact and highly efficient being capable of continuous operation, intermittent operation and empty-heating operation.

Steamers in current use, such as cooking steamers, convection ovens, cooking steam warmers, steamers for defrosting frozen food, steamers for processing tea leaves, steam baths for household use, steamers for cleaning, and steamers used in restaurants and hotels, are widely used as equipment for utilizing the steam they generate.Generally, fossil fuels (gas, petroleum, crude petroleum, coal and so forth) are burned as heat sources for large steamers in current use. This heating method, however, is not economical for compact steamers.

Relatively compact steamers in current use commonly employ electrical resistance heaters as a heat source. Such steamers obtain steam intermittently by spraying water on an iron plate which has been heated in advance with a heater or the heater's protecting tube from inside or beneath the plate.

Energy saving rate of electromagnetic induction steam boiler:

Because the iron container heats itself, the heat conversion rate is particularly high, which can reach more than 95%; the working principle of electromagnetic steam generator is that when some water enters the container, it will be heated into steam Drain, to ensure a fixed way of replenishing water, there will be continuous steam utilization.

Product Description

Industrial quality high pressure induction steamist boiler pure steam generator from china manufacturers 1) LCD Full-Automatically Intelligent Electronic Control System 2) High-quality Core Component——Electromagnetic induction heater 3) High-quality Components and Parts——Famous Brand Delixi Electrical Appliance 4) Multiple Safety Interlock Protection 5) Scientific Design and Attractive Appearance 6) Easy and Rapid Installation 7) Magnetic induction coil heat up boiling water Generate steam - Is Much More Eco-Friendly and Economical 8) Wide Application Range  

Item content / model	Rated power (KW)	Rated steam temperature (℃)	Rated current (A)	Rated steam pressure (mpa)	Evaporation (kg/h)	Thermal efficiency (%)	Input voltage (V/HZ)	Cross section of input power cord (MM2)	Steam outlet diameter	Relief valve diameter	Inlet diameter	Drainage diameter	Overall dimensions (mm)
HLQ-10	10	165	15	0.7	14	97	380/50HZ	2.5	DN20	DN20	DN15	DN15	450*750*1000
HLQ-20	20	165	30	0.7	28	97	380/50HZ	6	DN20	DN20	DN15	DN15	450*750*1000
HLQ-30	30	165	45	0.7	40	97	380/50HZ	10	DN20	DN20	DN15	DN15	650*950*1200
HLQ-40	40	165	60	0.7	55	97	380/50HZ	16	DN20	DN20	DN15	DN15	780*950*1470
HLQ-50	50	165	75	0.7	70	97	380/50HZ	25	DN20	DN20	DN15	DN15	780*950*1470
HLQ-60	60	165	90	0.7	85	97	380/50HZ	25	DN20	DN20	DN15	DN15	780*950*1470
HLQ-80	80	165	120	0.7	110	97	380/50HZ	35	DN25	DN20	DN15	DN15	680*1020*1780
HLQ-100	100	165	150	0.7	140	97	380/50HZ	50	DN25	DN20	DN25	DN15	1150*1000*1730
HLQ-120	120	165	180	0.7	165	97	380/50HZ	70	DN25	DN20	DN25	DN15	1150*1000*1730
HLQ-160	160	165	240	0.7	220	97	380/50HZ	95	DN25	DN20	DN25	DN15	1150*1000*1880
HLQ-240	240	165	360	0.7	330	97	380/50HZ	185	DN40	DN20	DN40	DN15	1470*940*2130
HLQ-320	320	165	480	0.7	450	97	380/50HZ	300	DN50	DN20	DN50	DN15	1470*940*2130
HLQ-360	360	165	540	0.7	500	97	380/50HZ	400	DN50	DN20	DN50	DN15	2500*940*2130
HLQ-480	480	165	720	0.7	670	97	380/50HZ	600	DN50	DN20	DN50	DN15	3150*950*2130
HLQ-640	640	165	960	0.7	900	97	380/50HZ	800	DN50	DN20	DN50	DN15	2500*950*2130
HLQ-720	720	165	1080	0.7	1000	97	380/50HZ	900	DN50	DN20	DN50	DN15	3150*950*2130

  Advantages & Features of Electromagnetic Induction Heating System: -Save electricity 30%~80%, especially for big power machine. - No influence on working environment: high frequency heating system has heat energy utilization rate of 90%+. - Heating fast, accurate temperature control - Can work for a long time in harsh environments - High frequency heating system make heating power bigger compare to traditional resistance wire heating. - No unsafe factors compare to traditional heating: temperature on surface of material container about 50°C~80°C.   Features of Induction Steam Generator: 1) LCD Full-Automatically Intelligent Electronic Control System 2) High-quality Core Component——Electromagnetic induction heater 3) High-quality Components and Parts——Famous Brand Electrical Appliance 4) Multiple Safety Interlock Protection 5) Scientific Design and Attractive Appearance 6) Easy and Rapid Installation 7) Magnetic induction coil heat up boiling water Generate steam - Is Much More Eco-Friendly and Economical 8) Wide Application Range

Applications of Electromagnetic Induction Heating Steam Generators 1, widely applied in food industry: like steam box, Dofu machine, sealing machine, sterilization tank, packing machine , coating machine and so on. 2, applications cases in biochemical industry: fermenter, reactor, sandwich pot, blender, Emulsifier and etc. 3, gradually be applied in washing industry like ironing table, washing machine dryer, drying and cleaning machine, washing machine and glue machine etc.  

Comparison of Different Types of Steam Generators
Steam Generator Type	Gas Steam Generator	Resistance Wire Steam Generator	Coal Steam Generator	Electromagnetic Heating Steam Generator
Energy Used	Gas by Fire	Resistance Wire by Electricity	Coal by Fire	Electromagnetic Heating by Electricity
Heat Exchange Rate	85%	88%	75%	96%
Need Someone on Duty	Yes	No	Yes	No
Temperature Control Accuracy	±8℃	±6℃	±15℃	±3℃
Heating Speed	Slow	Quick	Slow	Very quick
Working Environment	A little pollution after fired	Clean	pollution	Clean
Production Risk Index	Risk of gas leakage, complicated pipelines	Risk of electricity leakage pipe inner wall easy be scaling	Risk of high temperature, heavy pollution	No risk of leakage, water & electricity separated completely
Operational Performance	Complicated	Simple	Complicated	Simple

Application of induction heating steam generators|induction heating steam boilers:

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.

Electromagnetic Induction Heating Steam Generators

The principle of induction steam boilers|

electromagnetic induction steam generators|induction heating steam boilers

This invention relates to an induction steram boiler|electromagnetic induction steam generator which operates with a low-frequency alternating current electric power source. More specifically, this invention relates to an electromagnetic induction steam boiler which is compact and highly efficient being capable of continuous operation, intermittent operation and empty-heating operation.

Steamers in current use, such as cooking steamers, convection ovens, cooking steam warmers, steamers for defrosting frozen food, steamers for processing tea leaves, steam baths for household use, steamers for cleaning, and steamers used in restaurants and hotels, are widely used as equipment for utilizing the steam they generate.Generally, fossil fuels (gas, petroleum, crude petroleum, coal and so forth) are burned as heat sources for large steamers in current use. This heating method, however, is not economical for compact steamers.

Relatively compact steamers in current use commonly employ electrical resistance heaters as a heat source. Such steamers obtain steam intermittently by spraying water on an iron plate which has been heated in advance with a heater or the heater's protecting tube from inside or beneath the plate.

Energy saving rate of electromagnetic induction steam boiler:

Because the iron container heats itself, the heat conversion rate is particularly high, which can reach more than 95%; the working principle of electromagnetic steam generator is that when some water enters the container, it will be heated into steam Drain, to ensure a fixed way of replenishing water, there will be continuous steam utilization.

Product Description

Industrial quality high pressure induction steamist boiler pure steam generator from china manufacturers 1) LCD Full-Automatically Intelligent Electronic Control System 2) High-quality Core Component——Electromagnetic induction heater 3) High-quality Components and Parts——Famous Brand Delixi Electrical Appliance 4) Multiple Safety Interlock Protection 5) Scientific Design and Attractive Appearance 6) Easy and Rapid Installation 7) Magnetic induction coil heat up boiling water Generate steam - Is Much More Eco-Friendly and Economical 8) Wide Application Range  

Item content / model	Rated power (KW)	Rated steam temperature (℃)	Rated current (A)	Rated steam pressure (mpa)	Evaporation (kg/h)	Thermal efficiency (%)	Input voltage (V/HZ)	Cross section of input power cord (MM2)	Steam outlet diameter	Relief valve diameter	Inlet diameter	Drainage diameter	Overall dimensions (mm)
HLQ-10	10	165	15	0.7	14	97	380/50HZ	2.5	DN20	DN20	DN15	DN15	450*750*1000
HLQ-20	20	165	30	0.7	28	97	380/50HZ	6	DN20	DN20	DN15	DN15	450*750*1000
HLQ-30	30	165	45	0.7	40	97	380/50HZ	10	DN20	DN20	DN15	DN15	650*950*1200
HLQ-40	40	165	60	0.7	55	97	380/50HZ	16	DN20	DN20	DN15	DN15	780*950*1470
HLQ-50	50	165	75	0.7	70	97	380/50HZ	25	DN20	DN20	DN15	DN15	780*950*1470
HLQ-60	60	165	90	0.7	85	97	380/50HZ	25	DN20	DN20	DN15	DN15	780*950*1470
HLQ-80	80	165	120	0.7	110	97	380/50HZ	35	DN25	DN20	DN15	DN15	680*1020*1780
HLQ-100	100	165	150	0.7	140	97	380/50HZ	50	DN25	DN20	DN25	DN15	1150*1000*1730
HLQ-120	120	165	180	0.7	165	97	380/50HZ	70	DN25	DN20	DN25	DN15	1150*1000*1730
HLQ-160	160	165	240	0.7	220	97	380/50HZ	95	DN25	DN20	DN25	DN15	1150*1000*1880
HLQ-240	240	165	360	0.7	330	97	380/50HZ	185	DN40	DN20	DN40	DN15	1470*940*2130
HLQ-320	320	165	480	0.7	450	97	380/50HZ	300	DN50	DN20	DN50	DN15	1470*940*2130
HLQ-360	360	165	540	0.7	500	97	380/50HZ	400	DN50	DN20	DN50	DN15	2500*940*2130
HLQ-480	480	165	720	0.7	670	97	380/50HZ	600	DN50	DN20	DN50	DN15	3150*950*2130
HLQ-640	640	165	960	0.7	900	97	380/50HZ	800	DN50	DN20	DN50	DN15	2500*950*2130
HLQ-720	720	165	1080	0.7	1000	97	380/50HZ	900	DN50	DN20	DN50	DN15	3150*950*2130

  Advantages & Features of Electromagnetic Induction Heating System: -Save electricity 30%~80%, especially for big power machine. - No influence on working environment: high frequency heating system has heat energy utilization rate of 90%+. - Heating fast, accurate temperature control - Can work for a long time in harsh environments - High frequency heating system make heating power bigger compare to traditional resistance wire heating. - No unsafe factors compare to traditional heating: temperature on surface of material container about 50°C~80°C.   Features of Induction Steam Generator: 1) LCD Full-Automatically Intelligent Electronic Control System 2) High-quality Core Component——Electromagnetic induction heater 3) High-quality Components and Parts——Famous Brand Electrical Appliance 4) Multiple Safety Interlock Protection 5) Scientific Design and Attractive Appearance 6) Easy and Rapid Installation 7) Magnetic induction coil heat up boiling water Generate steam - Is Much More Eco-Friendly and Economical 8) Wide Application Range

Applications of Electromagnetic Induction Heating Steam Generators 1, widely applied in food industry: like steam box, Dofu machine, sealing machine, sterilization tank, packing machine , coating machine and so on. 2, applications cases in biochemical industry: fermenter, reactor, sandwich pot, blender, Emulsifier and etc. 3, gradually be applied in washing industry like ironing table, washing machine dryer, drying and cleaning machine, washing machine and glue machine etc.  

Comparison of Different Types of Steam Generators
Steam Generator Type	Gas Steam Generator	Resistance Wire Steam Generator	Coal Steam Generator	Electromagnetic Heating Steam Generator
Energy Used	Gas by Fire	Resistance Wire by Electricity	Coal by Fire	Electromagnetic Heating by Electricity
Heat Exchange Rate	85%	88%	75%	96%
Need Someone on Duty	Yes	No	Yes	No
Temperature Control Accuracy	±8℃	±6℃	±15℃	±3℃
Heating Speed	Slow	Quick	Slow	Very quick
Working Environment	A little pollution after fired	Clean	pollution	Clean
Production Risk Index	Risk of gas leakage, complicated pipelines	Risk of electricity leakage pipe inner wall easy be scaling	Risk of high temperature, heavy pollution	No risk of leakage, water & electricity separated completely
Operational Performance	Complicated	Simple	Complicated	Simple

Application of induction heating steam generators|induction heating steam boilers:

https://dw-inductionheater.com/electromagnetic-induction-heating-steam-generators?feed_id=107207&_unique_id=6245a4ef68786

Induction Heating Steel Mold

Induction Heating Steel Mold For Rubber Seal With High Frequency Heating System Objective To heat a steel mold evenly to 392ºF (200ºC) to be used on a press for rubber seal vulcanization Material Steel mold 13.4” (340mm) diameter, 2.16” (55mm) width, approximately 77.2 lbs (35kg) Temperature 392ºF (200ºC) Frequency 20kHz Equipment • DW-MF-70kW induction heating system, equipped with a remote workhead containing eight 0.3μF capacitors for a total of 0.6μF • An induction heating coil designed and developed specifically for this application. Process Two thirteen turn pancake coils are used to heat both sides of the mold simultaneously for 170 seconds to reach an external temperature of 392ºF (200ºC). The power is continually decreased over the next 390 seconds to reach a uniform temperature of 392ºF (200ºC) ± 41ºF (5ºC) throughout the mold. Results/Benefits Induction heating provides: • Repeatable and consistent heat • Quicker process time, increased production • Even distribution of heating                              

Induction Soldering Brass Tube-Pipe

Induction Soldering Brass Tube-Pipe-Tubing With RF Soldering Heating System Objective: Soldering two brass tubes measuring 3/4" and 1/4" together for use as cellular phone antennas. The lengths of tubes range from four (4) feet to twelve (12) feet, and must be soldered along the axial side. The joint is to be made using 60/40 Tin Lead Solder and Kestor Rosin paste flux. Material: Brass Tubes measuring 3/4" and 1/4" 60/40 Tin Lead Solder Kestor Rosin Flux Temperature: 3750F Application: Through the use of the the DW-UHF-40KW output solid state induction power supply along with a unique five (5) turn 12" long channel coil, the following results were achieved: 3750 F was reached and the solder flowed after a heating period of 35 seconds. A production rate of 24" per minute was determined to be adequate. A quality solder fillet was observed after heating and cooling Equipment: DW-UHF-40kW output solid state induction power supply including one (1) remote heat station containing two (2) capacitors, and a unique five (5) turn channel coil made from 3/16" copper tubing and measuring 1 1/4" by 12". Frequency: 385 kHz    

Brazing Copper to Brass Pipe With Induction

Brazing Copper to Brass Pipe With Induction Objective: Brazing several brass and copper assemblies used in water faucets Material braze, white flux Temperature 1350 °F 730°C Frequency 200 or 280 kHz (coil dependant) Equipment DW-UHF-10KW induction heating system, remote work head with two 1μF capacitors and a 3-turn helical coil Process: Three helical coils are used separately to braze a range of provided parts. Parts are assembled with flux and a braze alloy and then heated. The heat time varies from part to part with large parts taking less than 3 minutes and, the smaller parts heated in less than 20 seconds. After heating the parts are quench-cooled. Results/Benefits Repeatability: the inherent precision of induction heating supports a process which is highly repeatable. Economy: the process allows for the use of higher temperature braze alloy than a flame process

induction surface hardening steel screws

induction surface hardening steel screws

Objective:

Rapid surface induction hardening steel screws

Material: Steel screws .25” (6.3mm) diameter Temperature: 932 ºF (500 ºC) Frequency: 344 kHz Equipment • DW-UHF-10kW induction heating system, equipped with a remote workhead containing two 0.3μF capacitors for a total of 0.17μF • An induction heating coil designed and developed specifically for this application. Induction Hardening Process A three turn channel coil is used to heat 9 screws at a time. Power is applied for 3 seconds to reach 932 ºF (500 ºC) and achieve the required hardness. The screws travel through the coil head down in an automated system at a rate of 200 screws per minute Results/Benefits Induction heating provides: • Precise application of heat • Faster process time and production rates • Ability to incorporate into existing production lines • Repeatable, consistent results

Induction Catheter Tipping Heating

High Frequency Induction Catheter Tipping Heating Applications

This induction catheter tipping heating application is often needed in the Medical Industry for the manufacturing of catheter tubes.

With induction catheter tipping, RF energy raises the temperature on the stainless steel or brass mold, without physically contacting the mold or using an open flame. The tip of the catheter is then formed by inserting the plastic tubing into the heated die or mold to form the rounded edges. The rounded end of the catheter tube allows the tube to be safely inserted into the human with minimal trauma to body tissue. The mold will also have a wire that inserts into the tubing to prevent the formation of blockages. The precise and accurate temperature control capabilities of induction are ideal for this type of precise medical application. The molds are usually fitted with a water-cooled jacket used to cool the heated mold back to a defined start temperature which enables the induction system to be driven by a set time/cycle zone. Induction heating equipment for catheter tipping ensures a great degree of repeatability. The manufacturing process is fast and precise. Catheter tipping typically requires low power. HLQ has several low power units that are ideal for catheter tipping and will recommend the right equipment based on the parts and unique application requirements.   Heating Catheter Tipping Die Objective: To heat an aluminum catheter tipping die to above 2850F within 2 to 5 seconds for the forming of catheter material. Presently, heating is performed in 15 seconds with older induction equipment. The customer would like to use solid state induction heating equipment to reduce the heating times and develop a more efficient process. Material: Aluminum catheter tipping die measuring 3/8" OD and 2" long with a nonmagnetic sleeve over the heat zone. The catheter material was described as being similar to polyurethane plastic. Also, a 0.035" diameter steel wire was inserted into the catheter tube to prevent collapsing. Temperature: 5000F Application: The DW-UHF-3kW solid state induction power supply was determined to most efficiently produce the following results: --A heating time of 3.3 seconds to reach 5000F and form the catheter was achieved through the use of a two (2) over two (2) turn helical coil. --A quality catheter was formed by pressing 1/2" of the polyurethane tube into the mold while retaining shape through the use of a 0.035" wire to prevent collapsing of the tube. Laboratory results show that a substantial time decrease was accomplished which will allow for a significant increase in production while not sacrificing quality. Induction Heating Equipment: DW-UHF-3kWkW solid state induction power supply including a remote heat station containing one (1) capacitor totalling 1.2 µF. Frequency: 287 kHz

Induction Preheating Welding Steel Pipe

Induction Preheating Welding Steel Pipe With High Frequency Heating System Objective To preheat a steel pipe to 500ºF (260ºC) before welding. Material Steel shaft assembly 5” to 8” OD (127-203.2mm) with a 2” (50.8mm) heat zone. Temperature 500ºF (260ºC), if higher temperatures are required, heat time can be increased. Frequency 60 kHz Equipment • DW-HF-60kW induction heating system, equipped with a remote workhead containing eight 1.0 μF capacitors for a total of 8 μF. • An induction heating coil designed and developed specifically for this application. Process A multi-turn two position channel “C” coil, adjustable on a busbar is used to heat the desired heat zone. The coil is adjustable to fit various diameter pipes. The shaft is rotated in a fixture and heated for 3 minutes to achieve a temperature of 500ºF (260ºC). Results/Benefits Induction heating provides: • Preheating prevents shock to shaft which eliminates cracking in the welding phase. • Hands-free heating that involves no operator skill for manufacturing. • Even distribution of heating between the shank and the  sleeve.            

induction brazing automotive copper heating exchanger pipes

High frequency induction brazing automotive copper heating exchanger pipes

A manufacturer of appliances wants to achieve automation in their induction brazing process. Their goal is to be able to induction brazing automotive copper heating exchanger pipes. We carried out several tests to choose the best induction heating products which can fit their needs. The HLQ automated induction brazing system can be used for their specific process DW-UHF-20KW induction brazing machine The DW-UHF-20KW comes equipped with a  20kw induction heating system.This powerful induction heating solution can be successfully integrated into a production line. Equipment:  DW-UHF-20KW induction brazing machine Time: 12 sec. Materials: Copper pipes

Process: The robotic arm moves with great precision and allows complete control over the process. The alloy rings melt and perfectly braze all joints. One joint is being brazed for 12 seconds.

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

What is induction hardening?

What is induction hardening? Induction hardening uses induced heat and rapid cooling (quenching) to increase the hardness and durability of steel.Induction heating is a no-contact process that quickly produces intense, localized and controllable heat. With induction, only the part to be hardened is heated. Optimizing process parameters such as heating cycles, frequencies and coil and quench design results in the best possible outcomes. What are the benefits? Induction hardening boosts throughput. It is an extremely fast and repeatable process that integrates easily into production lines. With induction it is usual to treat individual workpieces. This ensures each separate workpiece is hardened to its own precise specifications. The optimized process parameters for each workpiece can be stored on your servers. Induction hardening is clean, safe and typically has a small footprint. And because only the part of the component to be hardened is heated, it is extremely energy-efficient. Where is it used? Induction heating is used to harden numerous components. Here are just a few of them: gears, crankshafts, camshafts, drive shafts, output shafts, torsion bars, rocker arms, CV joints, tulips, valves, rock drills, slewing rings, inner and outer races.

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

Shrink Fitting Assemble Connecting Rods

Induction Shrink Fitting Assemble Connecting Rods With IGBT Heating Units Objective Assemble connecting rods with a more accurate control of the heat Material Rod has an OD of .9125” (23.18mm), knuckle has an ID of .9125” (23.18mm) with an interference of .0001” (.0025mm). Knuckle assembly is forged steel Temperature 400 ºF (204 ºC) Frequency 210 kHz Equipment • DW-UHF- 3.5 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 six turn helical coil is used to heat the connecting rod for 13 seconds. The coil is perpendicular to the axis of the bore to promote even heating around the circumference. The connecting rod is then assembled with the piston for shrink fitting. Results/Benefits Induction heating provides: • More accurate control of heat vs a flame burner. Only heats knuckle, not the whole part. • Lower temperature used to prevent discoloring. • Increased productivity due to repeatability & ease of operation. A foot pedal & timer is used. • No product contamination.            

Induction Preheating Welding Steel Pipe

Induction Preheating Welding Steel Pipe With High Frequency Heating System Objective To preheat a steel pipe to 500ºF (260ºC) before welding. Material Steel shaft assembly 5” to 8” OD (127-203.2mm) with a 2” (50.8mm) heat zone. Temperature 500ºF (260ºC), if higher temperatures are required, heat time can be increased. Frequency 60 kHz Equipment • DW-HF-60kW induction heating system, equipped with a remote workhead containing eight 1.0 μF capacitors for a total of 8 μF. • An induction heating coil designed and developed specifically for this application. Process A multi-turn two position channel “C” coil, adjustable on a busbar is used to heat the desired heat zone. The coil is adjustable to fit various diameter pipes. The shaft is rotated in a fixture and heated for 3 minutes to achieve a temperature of 500ºF (260ºC). Results/Benefits Induction heating provides: • Preheating prevents shock to shaft which eliminates cracking in the welding phase. • Hands-free heating that involves no operator skill for manufacturing. • Even distribution of heating between the shank and the  sleeve.            

Induction Annealing Copper Tubes

Simultaneously Induction Annealing Copper Tubes

Objective Uniformly heat two copper tubes simultaneously to 800°F (426°C) in under 10 seconds with induction heating.

Equipment DW-HF-45kw induction heater Helical coil Material • Two copper tubes – OD: 0.69’’ (1.75 cm) – ID: 0.55’’ (1.40 cm) – Length: 5.50’’ (14.0 cm). Key Parameters Power: 35kW Temperature: 842°F (450°C) Time: 7sec

Process:

1. The two copper tubes were placed together in the coil.
2. Induction heat was applied for 8s.

Results/Benefits:

• Improved process control for uniform heating to a desired temperature
• Power on demand and rapid, consistent heat cycles
• Technology without pollution, which is both clean and safe

Induction Brazing Heating Exchanger Copper Pipes

Objective Induction Brazing Heating Exchanger copper pipes to coppers Industry Various industries Base material Copper tubes Cu-DHP acc. to EN12735 or EN1057 – Diameter / thickness of external tube: 12.5 x 0.35 and 16.75 x 0.4 – Type of assembly: lap joint Other materials Brazing alloy rings

Equipment DW-UHF-20KW induction brazing machine HLQ Custom Coil Key Parameters Power: 12kW Time: ≈ 5s

Process A manufacturer of heating exchangers for various industries wanted to increase operator safety and production rate during the process of induction brazing. We received a sample of a heat exchanger which was a part of an actual assembly (more than 10 m long). The goal was to determine the most suitable design for a custom coil which will allow for the induction brazing of two joints to be performed simultaneously. HLQ team recommended using the DWS which is a mobile induction heating solution that can be utilized as a hand-held unit or can be integrated with a robotic arm for automated production lines. Тhe performed tests matched the exact position of the heat exchanger on the production to simulate actual working conditions. We used a custom-designed elliptical coil with a positioning fixture to help the operator achieve repeatable results, as well as increase the production rate by brazing 2 joints for 5 sec. As a result, the brazed connection becomes extremely secure and leak-proof. Compared to gas torch brazing, induction heating does not produce an open flame, thus it is much safer for the operator. Fast process and repeatability are guaranteed. Heat exchangers are devices that are widely used in many industries – space heating, refrigeration, air conditioning, power stations, chemical plants, petrochemical plants, petroleum refineries, natural gas processing, and sewage treatment. Benefits

• Safe heating with no open flame
• Precise control over time and temperature resulting in improved quality and consistent result
• A repeatable process, not operator dependent
• Energy efficient induction heating