induction brazing stainless steel to steel

High frequency magnetic induction brazing stainless steel to steel process

HLQ team was provided with 2 different parts to be brazed in our test laboratory. Objective: Induction Brazing of a 0.15’’/ 3.81mm stainless steel pin to a steel base. Equipment:  DW-UHF-6KW-III handheld induction brazing system  Industry: Appliances & HVAC Materials: Steel hexagon (base 1’’/ 25.4 mm diameter; 0.1’’/ 2.54 mm wall thickness) A stainless steel pin (0.15’’/ 3.81 mm) Other Materials:  All-purpose black brazing flux Power: 1.43 kW Temperature: 1400 °F/ 760°C Time: 8 seconds Process: The two workpieces were carefully positioned together. All-purpose induction brazing black flux was added because it is ideal for high-temperature applications where rapid, localized heating is needed. The process of induction brazing was performed successfully within 8 seconds by using the  DW-UHF-6KW-III handheld induction brazing system, producing the induction heating power of 1.43 kW at 1400 °F/ 760°C. https://dw-inductionheater.com/high-frequency-magnetic-induction-brazing-stainless-steel-to-steel-process.html?feed_id=221386&_unique_id=64c899b3307e9

Induction Heating Basic

Induction Heating Basics

Induction heating takes place in an electrically conducting object (not necessarily magnetic steel) when the object is placed in a varying magnetic field. Induction heating is due to the hysteresis and eddy-current losses. Induction heating is the process of heating an electrically conducting object (usually a metal) by electromagnetic induction, through heat generated in the object by eddy currents. An induction heater consists of an electromagnet and an electronic oscillator that passes a high-frequency alternating current (AC) through the electromagnet. The rapidly alternating magnetic field penetrates the object, generating electric currents inside the conductor, called eddy currents. The eddy currents flowing through the resistance of the material heat it by Joule heating. In ferromagnetic (and ferrimagnetic) materials like iron, heat may also be generated by magnetic hysteresis losses. The frequency of current used depends on the object size, material type, coupling (between the work coil and the object to be heated) and the penetration depth. Hysteresis losses only occur in magnetic materials such as steel, nickel, and very few others. Hysteresis loss states that this is caused by friction between molecules when the material is magnetized first in one direction, and then in the other. The molecules may be regarded as small magnets which turn around with each reversal of direction of the magnetic field. Work (energy) is required to turn them around. The energy converts into heat. The rate of expenditure of energy (power) increases with an increased rate of reversal (frequency). Eddy-current losses occur in any conducting material in a varying magnetic field. This causes heading, even if the materials do not have any of the magnetic properties usually associated with iron and steel. Examples are copper, brass, aluminum, zirconium, nonmagnetic stainless steel, and uranium. Eddy currents are electric currents inducted by transformer action in the material. As their name implies, they appear to flow around in swirls on eddies within a solid mass of material. Eddy-current losses are much more important than hysteresis losses in induction heating. Note that induction heating is applied to nonmagnetic materials, where no hysteresis losses occur. For the heating of steel for hardening, forging, melting, or any other purposes which require a temperature above Curie temperature, we cannot depend upon hysteresis. Steel loses its magnetic properties above this temperature. When steel is heated below the Curie point, the contribution of hysteresis is usually so small that it can be ignored. For all practical purposes, the I²R of the eddy currents is the only way in which electrical energy can be turned into heat for induction heating purposes. Two basic things for induction heating to occur:

• A changing magnetic field
• An electrically conductive material placed into the magnetic field

high frequency induction hardening camshafts process

Induction heating is the preferred method for hardening camshafts. The objective of this application  is to harden a variety of steel samples within several seconds.If induction heating is integrated into the production lines, each camshaft can be hardened with great controllability and repeatability. Our machines allow you to fully adjust the heat parameters. Industry: Automotive Equipment: DW-UHF-20KW induction hardeing machine Power: 13.37kW Time: 5 secs. Coil: Helical induction heating coil. The Process: Camshafts are widely used in the automotive industry as a main part of the combustion engines. Due to their overall length and high peripheral speed, they suffer high tensile and torsion stresses during operation, which may significantly reduce their operating life. Softer material favors overcoming these stresses, which, however, results in excessive surface wearing due to the friction between the camshaft and the engine valves. The goal of the performed hardening process is to increase the wear resistance of the workpiece surface, while the core of the sample remains soft to preserve its tensile strength and torsion resistance. For this purpose, the surface has to be heated to a particular temperature (usually about 800°C) followed by proper cooling. The heating and cooling rates should be strictly observed in order to obtain particular material features. The core of the camshaft should be prevented from heating during the hardening process to preserve its softness. DW-UHF induction heating systems are widely used in the automotive industry.   [wpforms id="3947"]

 

Induction Brazing Copper to Stainless Steel Process

High Frequency Induction Brazing Copper to Stainless Steel Process Technology

Objective The objective of this induction brazing copper to stainless steel using a DW-UHF-40kw induction heating power supply with a custom heating station Equipment DW-UHF-40KW Induction Heating Power Supply HLQ custom coil Key Parameters Power: 23.65 kW Temperature: Approximately 1300°F (704)°C Time: 3.5 mins

Materials Cooper 4.5″ OD 0.5″ Wall Thickness Stainless Steel  4″ OD Braze Joint 2″

Process: In order to start the induction brazing of copper to stainless steel the part was centered on a turntable. The induction brazing coil was then positioned around the copper because it is less efficiently heated than stainless steel. As the part was rotating, approximately 25kW were being applied to the coil. Once the brazed joint was close to the ideal brazing temperature, the alloy was hand fed onto the joint. The induction brazing of cooper to stainless steel was completed and successful.

Results/Benefits: The result of the induction brazing copper to stainless steel application testing was a positive one, the induction brazing was completed and the copper to stainless steel was done seamlessly. This test resulted in high quality and repeatability of the brazed joints, increased productivity and control of the time and temperature.

 

https://dw-inductionheater.com/high-frequency-induction-brazing-copper-to-stainless-steel-process.html?feed_id=221311&_unique_id=64c7e28e1adb8

induction curing

What is induction curing?

How does induction curing work? Simply put, line power is converted to alternating current and delivered to a work coil which creates an electromagnetic field within the coil. The piece with the epoxy on it can be metal or a semiconductor such as carbon or graphite. To cure epoxy on non-conductive substrates such as glass, an electrically conductive susceptor can be used to transfer the heat to the non-conductive material. [caption id="attachment_6981" align="alignnone" width="721"] induction curing principle-theory[/caption]

What are the benefits of induction curing?

Single component epoxy adhesives that are heat cured can use heat from various sources. The most typical is an oven but heat air guns, bake plates and induction curing are also used. Induction curing can greatly reduce the amount of time required to cure the epoxy and minimize the effects of heat on surrounding components as induction heating delivers heat precisely to the adhesive area.

Is induction curing a good option for my application?

Providing your induction heating equipment specialist and your epoxy adhesive manufacturer information on the following topics will help them to make the best recommendation. 1. Materials or substrates being bonded – Understanding what the substrates are will help determine the heating rate and power needed to cure the adhesive. For example iron heats with less power than is needed to heat aluminium. 2. Size of the components being bonded – Smaller parts require a higher frequency for efficient heating. Larger areas benefit from a lower frequency. 3. Epoxy requirements – There is a min/max threshold for curing epoxy. The minimum temperature required to effect cure and the maximum temperature allowed prior to the breakdown of the epoxy.

Induction Curing for Bonding of Quartz Chip to a Steel Cylinder

A company in the Automotive industry is looking for an induction heating system that can reach the temperature of 175° C (347°F) and hold it within the tight tolerance of +/- 3 C. Induction heating will heat a steel cylinder to cure an adhesive for bonding of a quartz chip. Induction heating is a preferred method because it provides faster, controlled and more uniform heating. Industry: Automotive Equipment: DW-UHF-10kW induction heating system is recommended for this curing application to ramp up and hold the desired temperature. Process: The goal of this induction curing application is to heat two sides of a steel cylinder which is 1.064” (2.70 cm) OD, 7.25” (18.41 cm) long with a 1” (2.54 cm) heat zone up to 175 C (347°F) and hold that temperature for 60 seconds in order to perform bonding application. The desired temperature was reached in 13 seconds. A K-type temperature controller was used to measure the temperature. [caption id="attachment_6979" align="alignnone" width="1024"] induction curing process[/caption] Induction Curing for Bonding of Quartz Chip to a Steel Cylinder

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

https://dw-inductionheater.com/induction-brazing-heating-exchanger-copper-pipes.html?feed_id=221236&_unique_id=64c72ba5e37d8

induction heating graphite susceptor

Induction heating graphite susceptor for glass reflow for X-ray tubes Objective Heat graphite susceptor for glass reflow in the manufacturing of x-ray tubes Material Glass disc 0.98 x 0.12 “ (25 x 3mm), graphite susceptor, stainless steel holder, Glass bell jar 5.9” (150mm) OD Temperature 1742 ºF (950º C) Frequency 80 kHz Equipment • DW-HF-25kW induction heating system, equipped with a remote workhead containing eight 0.3 μF capacitors for a total of 2.4 μF • An induction heating coil designed and developed specifically for this application. Process A two turn helical coil is used for heating. Six graphite susceptors are placed in the nitrogen atmosphere with glass discs and a stainless steel holder. In 32 seconds the required temperature of 1742 ºF (950º C) is reached causing the glass to reflow & the stainless steel holder to melt through the glass. Results/Benefits Induction heating provides: • Increased production, customer currently heating 4 susceptors • 50% lower energy consummation • Even distribution of heating

Induction Brazing Machine

Induction Brazing Machine&Soldering Equipment

Main characteristics:

    1.  IGBT module and inverting technologies of the first generation been used.

    2.  Simple structure and light weight and easy for maintenance.

    3.  Simple to operat ,afew minutes is enough to learn it.

    4.  Simple to install,installation can be done by unprofessional person very easily.

    5.  advantages of the model with timer,the power and the operatingtime of the heating period and the rain period  can be preset repectively,to realize a simple heating curve,this model is suggested to use for batch production to improve the repeatability.

   6.   The separated models are designed to fit the dirty surrounding of some cases.

Specifications：

Series	Model		Input power Max	Input current Max	Oscillate frequency	Input Voltage	Duty cycle
M . F .	DW-MF-15 Induction Generator		15KW	23A	1K-20KHZ According to the application	3*380V 380V±20%	100%
	DW-MF-25 Induction Generator		25KW	36A
	DW-MF-35Induction Generator		35KW	51A
	DW-MF-45 Induction Generator		45KW	68A
	DW-MF-70 Induction Generator		70KW	105A
	DW-MF-90 Induction Generator		90KW	135A
	DW-MF-110 Induction Generator		110KW	170A
	DW-MF-160 Induction Generator		160KW	240A
	DW-MF-45 Induction Heating Rod Forging Furnace		45KW	68A	1K-20KHZ	3*380V 380V±20%	100%
	DW-MF-70 Induction Heating Rod Forging Furnace		70KW	105A
	DW-MF-90 Induction Heating Rod Forging Furnace		90KW	135A
	DW-MF-110 Induction Heating Rod Forging Furnace		110KW	170A
	DW-MF-160 Induction Heating Rod Forging Furnace		160KW	240A
	DW-MF-15   Induction Melting Furnace		15KW	23A	1K-20KHZ	3*380V 380V±20%	100%
	DW-MF-25   Induction Melting Furnace		25KW	36A
	DW-MF-35   Induction Melting Furnace		35KW	51A
	DW-MF-45   Induction Melting Furnace		45KW	68A
	DW-MF-70   Induction Melting Furnace		70KW	105A
	DW-MF-90   Induction Melting Furnace		90KW	135A
	DW-MF-110 Induction Melting Furnace		110KW	170A
	DW-MF-160 Induction Melting Furnace		160KW	240A
	DW-MF-110 Induction Hardening Equipment		110KW	170A	1K-8KHZ	3*380V 380V±20%	100%
	DW-MF-160Induction Hardening Equipment		160KW	240A
H . F .	DW-HF-04 Series	DW-HF-4KW-A	4KVA	15A	100-250KHZ	Single phase 220V	80%
	DW-HF-15 Series	DW-HF-15KW-A DW-HF-15KW-B	15KVA	32A	30-100KHZ	Single phase 220V	80%
	DW-HF-25 Series	DW-HF-25KW-A DW-HF-25KW-B	25KVA	23A	20-80KHZ	3*380V 380V±10%	100%
	DW-HF-35 Series	DW-HF-35KW-B	35KVA	51A
	DW-HF-45 Series	DW-HF-45KW-B	45KVA	68A
	DW-HF-60 Series	DW-HF-60KW-B	60KVA	105A
	DW-HF-80 Series	DW-HF-80KW-B	80KVA	130A
	DW-HF-90 Series	DW-HF-90KW-B	90KVA	160A
	DW-HF-120 Series	DW-HF-120KW-B	120KVA	200A
U . H . F .	DW-UHF-3.2KW		3.2KW	13A	1.1-2.0MHZ	Single phase220V ±10%	100%
	DW-UHF-4.5KW		4.5KW	20A
	DW-UHF-045T		4.5KW	20A
	DW-UHF-045L		4.5KW	20A
	DW-UHF-6.0KW		6.0KW	28A
	DW-UHF-06A		6.0KW	28A
	DW-UHF-6KW-B		6.0KW	28A
	DW-UHF-10KW		10KW	15A	100-500KHZ	3*380V 380V±10%	100%
	DW-UHF-20KW		20KW	30A	50-250KHZ
	DW-UHF-30KW		30KW	45A	50-200KHZ
	DW-UHF-40KW		40KW	60A	50-200KHZ
	DW-UHF-60KW		60KW	90A	50-150KHZ

 

Induction Brazing Carbide To Steel

Objective Induction Brazing carbide to steel parts Equipment DW-HF-15kw Induction Heating Power Supply HLQ custom coil Key Parameters Power: 5.88 kW Temperature: Approximately 1500°F (815°C) Time: 10 sec Materials Coil-  2 helical turns (20 mm ID) 1 planar turn (40 mm OD, 13 mm Height) Carbide-  13 mm OD, 3 mm wall thickness Steel piece– 20 mm OD, 13 mm ID

Process:

1. To demonstrate elimination of “hand feeding” the alloy, we formed the alloy into a ring to tightly fit over the center post tube. This method provides a uniform amount for each cycle, resulting in uniform joints and wetting.
2. The custom made coil was then placed over the steel piece, where is was set for 10 seconds to heat the alloy.
3. The alloy was heated at approximately 1500°F (815)°C
4.  The whole piece is left alone and cooled with ambient air

Results/Benefits:

• Induction Brazing was successful all in under 15 seconds with 8kW
• High quality and repeatability of the brazed joints
• Increased productivity
• Rings will need to be developed for specific joints to prevent the use of too much alloy
• Precise control of the time and temperature

https://dw-inductionheater.com/high-frequency-induction-brazing-carbide-to-steel-process.html?feed_id=221161&_unique_id=64c6749551518

induction preheating copper bars

induction preheating copper bars to temperature

Objective: To preheat two copper bars to temperature within 30 seconds; the client is looking to replace a competitor’s 5kW induction heating system that is delivering unsatisfactory results Material:  Copper bars (1.25” x 0.375” x 3.5”/31mm x 10mm x 89mm ) - Thermal indicating paint Temperature: 750 ºF (399 ºC) Frequency: 61 kHz Equipment : DW-HF- 15kW, 50-150 kHz induction heating power supply with a remote workhead containing two 1.0 μF capacitors - A dual-position, multi-turn helical coil designed and developed for this heating application Induction Heating Process: A thermal indicating paint was applied to the face of the copper bar, and the bar was placed inside the coil. The part was heated for 30 seconds and it reached temperature. The next step in the process was to heat two parts in a dual-position coil. The parts were inserted into the coil and heated to temperature within 30 seconds. In order to heat four parts to temperature within the same time period, two power supplies and two dual-position coils are required. Results/Benefits -- Speed: Induction was able to meet their time requirements. -- Process development: The HLQ lab team was able to help the client develop a new heating process that achieved better results than what they saw with their old, inferior induction heating system -- Process efficiency: With induction and the right induction partner, a time, energy and space efficient system was designed

Induction Brazing Brass Studs to Copper Pipes

Induction Brazing Brass Studs to Copper Pipes

Objective:

Induction brazing brass studs to copper pipes

The Client:

A manufacturer of coils for industrial heating applications.

Equipment:

DW-UHF-40KW Induction Brazing Systems – two modules.

Materials: Brass stud ( size:  25mm diameter, 20 mm height ) Power: 30 kW

The Process:  The main challenge during this induction brazing process is to ensure that the design of the coil is one that eases the technician to position it in the most convenient way. The induction coil should allow for the second stud to be pre-heated without melting the first one. First, the electrolytic copper section is wound on a steel former by a gas torch while an equal spacing between the turns is maintained. Then, the copper turn is heated close to the required temperature and while the power is ON, the technician should make sure to manually position the brass stud with the brazing ring at the designated centre. During the process of brazing, the induction coil is moving at a speed of 58 mm per minute – 33 kW. If the power is increased, the speed changes accordingly. Results and Conclusions:

• A fast, clean and safe induction brazing process
• Guaranteed repeatability
• Precise control of time and temperature

https://dw-inductionheater.com/induction-brazing-brass-studs-to-copper-pipes.html?feed_id=221086&_unique_id=64c5bde9f35f8

What is induction annealing?

What is induction annealing? This process heats metals that have already undergone significant processing. Induction annealing reduces hardness, improves ductility and relieves internal stresses. Full-body annealing is a process where the complete workpiece is annealed. With seam annealing (more accurately known as seam normalizing), only the heat-affected zone produced by the welding process is treated. What are the benefits? Induction annealing and normalizing delivers fast, reliable and localized heat, precise temperature control, and easy in-line integration. Induction treats individual workpieces to exact specifications, with control systems continuously monitoring and recording the entire process. Where is it used? Induction annealing and normalizing is widely used in the tube and pipe industry. It also anneals wire, steel strips, knife blades and copper tubing. In fact, induction is ideal for virtually any annealing task. What equipment is available? Each DAWEI Induction annealing system is built to satisfy specific requirements. At the heart of each system is an DAWEI Induction Heating generator that features automatic load matching and a constant power factor at all power levels. Most of our delivered systems also feature custom-built handling and control solutions.

Brazing Carbide to Steel Part With Induction Heating

Objective Brazing carbide to steel part Equipment DW-UHF-6kw Induction Heating Power Supply ultra high frequency custom coil Key Parameters Power: 1.88 kW Temperature: Approximately 1500°F (815°C) Time: 14 sec Materials Coil-  2 helical turns (20 mm ID) 1 planar turn (40 mm OD, 13 mm Height) Carbide-  13 mm OD, 3 mm wall thickness Steel piece– 20 mm OD, 13 mm ID

Induction Brazing Process:

1. To demonstrate elimination of “hand feeding” the alloy, we formed the alloy into a ring to tightly fit over the center post tube. This method provides a uniform amount for each cycle, resulting in uniform joints and wetting.
2. The custom made coil was then placed over the steel piece, where is was set for 14 seconds to heat the alloy.
3. The alloy was heated at approximately 1500°F (815)°C
4.  The whole piece is left alone and cooled with ambient air

Results/Benefits:

• Brazing was successful all in under 20 seconds with 2-kW
• High quality and repeatability of the brazed joints
• Increased productivity
• Rings will need to be developed for specific joints to prevent the use of too much alloy
• Precise control of the time and temperature

induction brazing stainless steel tubing process

Induction Brazing stainless steel tubing and stainless steel fittings Technology

Objective Induction Brazing stainless steel tubing and stainless steel fittings Equipment DW-UHF-20kw 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

https://dw-inductionheater.com/induction-brazing-stainless-steel-tubing-process.html?feed_id=221011&_unique_id=64c506fdeff3e