Induction Brazing Principle-Theory

Induction Brazing Technology

Induction Brazing Principle|Theory Brazing and soldering are processes of joining similar or dissimilar materials using a compatible a filler material. Filler metals include lead, tin, copper, silver, nickel and their alloys. Only the alloy melts and solidifies during these processes to join the work piece base materials. The filler metal is pulled into the joint by capillary action. Soldering processes are conducted below 840°F (450°C) while brazing applications are conducted at temperatures above 840°F (450°C) up to 2100°F (1150°C). The success of these processes depends upon the assembly’s design, clearance between the surfaces to be joined, cleanliness, process control and the correct selection of equipment needed to perform a repeatable process. Cleanliness is ordinarily obtained by introducing a flux which covers and dissolves dirt or oxides displacing them from the braze joint. Many operations are now conducted in a controlled atmosphere with a blanket of inert gas or combination of inert / active gasses to shield the operation and eliminate the need for a flux. These methods have been proven on a wide variety of material and part configurations replacing or complimenting atmosphere furnace technology with a just in time - single piece flow process. Brazing Filler Materials Brazing filler metals can come in a variety of forms, shapes, sizes and alloys depending on their intended use. Ribbon, preformed rings, paste, wire and preformed washers are just a few of the shapes and forms alloys that can be found. The decision to use a particular alloy and/or shape is largely dependent on the parent materials to be joined, placement during processing and the service environment for which the final product is intended. Clearance Affects Strength Clearance between the faying surfaces to be joined determines the amount of braze alloy, capillary action / penetration of the alloy and subsequently the strength of the finished joint. The best fit up condition for conventional silver brazing applications are 0.002 inches (0.050 mm) to 0.005 inches (0.127 mm) total clearance. Aluminum is typically 0.004 inches (0.102 mm) to 0.006 inches (0.153 mm). Larger clearances up to 0.015 inches (0.380 mm) usually lack sufficient capillary action for a successful braze. Brazing with copper (above 1650°F / 900°C) requires the joint tolerance kept to an absolute minimum and in some cases press fit at ambient temperatures to assure minimum joint tolerances while at the brazing temperature. Induction Heating Theory Induction systems provide a convenient and precise way to quickly and efficiently heat a selected area of an assembly. Consideration must be given to the selection of power supply operating frequency, power density (kilowatt applied per square inch), heating time, and induction coil design to provide the required depth of heating in a specific braze joint. Induction heating is non-contact heating by means of transformer theory. The power supply is an AC source to the induction coil that becomes the primary windings of the transformer while the part to be heated is the transformer’s secondary. The work piece heats by the base materials’ inherent electrical resistivity to the induced current flowing in the assembly. Current passing through an electrical conductor (the workpiece) results in heating as current meets resistance to its flow. These losses are low in current flowing through aluminum, copper and their alloys. These non-ferrous materials require additional power to heat than their carbon steel counterpart. The alternating current tends to flow on the surface. The relationship between the frequency of the alternating current and the depth it penetrates the part is known as the reference depth of heating. Part diameter, material type and wall thickness can have an effect on heating efficiency based on the reference depth.  

Brazing Steel To Steel Pipe With Induction

Brazing Steel To Steel Pipe With Induction  Objective: To braze O-ring Face (ORFS) sleeve or male connector to a steel tube. Material • Steel tube, 1 inch (2.54 cm) OD • O-ring Face Seal sleeve and a male connector fittings • Preform braze rings • White SureFlow flux • Steel support mandrel Temperature 1300 ºF (704 ºC) Frequency 200 kHz Equipment • DW-UHF-20KW induction heating system, equipped with a remote workhead containing two (2) 1.5 μF capacitors (for a total of 0.75 μF). • An induction heating coil designed and developed specifically for this application. Process A four-turn 2.75 inch (7.0 cm) ID helical coil is used for heating both the steel tube and the ORFS sleeve or the ORFS male connector. This coil is designed to braze either the sleeve or male connector to the tube. The parts to be brazed are assembled with flux and heated for 45 seconds. Pressure is applied to the tube to make sure it is inserted fully into the fittings as the braze ring flows. Results/Benefits Advantages : • Large Inner diameter of coil allows for easy loading and unloading of parts • With efficient energy coupling of the coil to the fittings overheating is avoided. https://dw-inductionheater.com/brazing-steel-to-steel-pipe-with-induction.html?feed_id=229956&_unique_id=65415f6089eec

Induction Bar End Heating Furnace

HLQ Induction Equipment Co is the World leader in the design and manufacture of induction heating products including those for induction bar end heating applications. Higher production rates can be achieved with the use of multiple solenoid coils while channel induction coils facilitate material handling of long bars through the use of chain conveyors to continuously feed the bars through the C-shaped coil. Parameter of induction bar end heating furnace:

		DW-MF-200	DW-MF-250	DW-MF-300	DW-MF-400	DW-MF-500	DW-MF-600
Input Voltage		3phases, 380V/410V/440V , 50/60Hz
Max Input Current		320A	400A	480A	640A	800A	960A
Oscillating frequency		0.5KHz^20KHz ( Oscillating frequency will be customized according to the size of heating parts)
Duty Cycle Loading		100%,24h continuously work
Cooling Water Desires		0.1MPa
Dimension	Host	1000X800X1500mm			1500X800X2800mm	850X1700X1900mm
	Extension	extension will be customized according to the material and size of heating parts
Weight		110kg	150kg	160kg	170kg	200kg	220kg
		Depend on the dimension of extension

Induction Brazing Carbide to Steel

Induction Brazing Carbide to Steel  Objective: Braze a carbide sleeve to a steel 'T' shank Material :2.0" (51mm) OD carbide sleeve, 1.0" (25.5mm) high braze joint, 1.5 " (38 mm) steel 'T' , 50% silver braze ring Temperature: 1292 ºF (700 ºC) Frequency: 257 kHz Equipment • DW-UHF-6KW-I induction heating system, equipped with a remote workhead containing two 0.66μF capacitors for a total of 1.32 μF. • An induction heating coil designed and developed specifically for this application. Process A pancake/helical combination coil is used to heat the assembly. The coil design allows easy loading and unloading of the parts without having to rotate them. A few minutes after the start of the heat cycle the heat pattern normalizes and becomes very uniform. For better joint quality a chamfered groove is machined in the steel shank to locate and seat the braze ring. The braze alloy flows into the joint creating a strong, aesthetic bond. The amount of braze alloy heated each cycle is controlled well by the braze ring. Results/Benefits Induction heating provides: • Hands-free brazing which requires no special operator skills for manufacturing • Precise, even heat is applied and is divided equally between the shank and the carbide. This provides an even flow of the braze alloy as the parts reach brazing temperatures. https://dw-inductionheater.com/induction-brazing-carbide-to-steel.html?feed_id=229926&_unique_id=6540a897027ae

High Frequency Induction Brazing Copper Wire

Objective High frequency induction Braze a 5.3 sq mm (10 gauge) and a 0.5 sq mm (20 gauge) copper wire using induction with an open C-coil. Equipment DW-UHF-6KW-III handheld induction brazing heater Open C-coil Flexible Leads Materials • 10 gauge (5.3 sq mm) copper wire • 20 gauge wire (0.5 sq mm) copper wire • Brazing alloy • Brazing flux

Test 1 Power: 2 kW Temperature: 815° C (1500° F) Time: 42 sec

Test 2 Power: 2 kW Temperature: 815° C (1500° F) Time: 38 sec

Test 2 Power: 4.86 kW Temperature: 815° C (1500° F) Time: 10 sec

Results and Conclusions: Brazing the two types of copper wire is possible with the DW-UHF-6KW-III handheld induction brazing System with 1m (3.3 ft) flexible leads and an open C-coil. For even faster braze times, a DW-UHF-10kw induction System is recommended.

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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

 

Brazing Copper Bars with Induction

Brazing Copper Bars with Induction Objective: To braze bus bar assemblies together Material: • 2 copper bus bars 6" (152.4mm) wide, 2' (609.6mm)long, 2 copper bars 6"(152.4mm) wide, 18" (457.2)long & 3/8" (9.65mm) thick • braze shim preforms and white flux Temperature: 1292 ºF (700 ºC) Frequency: 80 kHz Equipment • DW-UHF-60KW induction heating system, equipped with a remote workhead containing eight 1.0 μF capacitors for a total of 2.0 μF. • An induction heating coil, designed and developed specifically for this application Process: A three-turn helical coil is used to heat the assembly. Three braze shim preforms are placed between the plates and white flux is applied to the assembly. It is heated for 5 minutes to evenly flow the braze alloy. A high current capable, aesthetic looking braze zone is produced. Results/Benefits Induction heating provides: • Consistently produced, quality parts • Heat into the part that is divided equally between the copper pieces, allowing for even flow and consistent use of braze • Hands-free operation that doesn't require skilled operators https://dw-inductionheater.com/brazing-copper-bars-with-induction.html?feed_id=229896&_unique_id=653ff1a5c894a

Magnetic Induction Heater Manufacturer

Magnetic Induction Heater  is a process equipment which is used to melt,braze,forge,bond,heat treating,harden or soften metals or other conductive materials. For many modern manufacturing processes, Magnetic induction heating equipment offers an attractive combination of speed, consistency and control.The basic principles of magnetic induction heating have been understood and applied to manufacturing since the 1920s. During World War II, the technology developed rapidly to meet urgent wartime requirements for a fast, reliable process to harden metal engine parts. More recently, the focus on lean manufacturing techniques and emphasis on improved quality control have led to a rediscovery of induction technology, along with the development of precisely controlled, all solid state induction power supplies.

Magnetic Induction Heater relies on the unique characteristics of induction heating radio frequency (RF) energy - that portion of the electromagnetic spectrum below infrared and microwave energy. Since heat is transferred to the product via electromagnetic waves, the part never comes into direct contact with any flame, the inductor itself does not get hot, and there is no product contamination. When properly set up, the process becomes very repeatable and controllable.

Main Characteristics：

　  1.IGBT module and soft switiching inverting technologies are as in the production of the generator,higher reliability can be do.　

　  2. Small and portable ,compared with SCR controlled machine only 1/10 working space is needed. 3.  High efficiency to save energy,high efficiency and power far can be maintained

　  4.  The generator is adatable in a large frequency range from 1KHZ to 1100KHZ,installation can be done very easily according to our manual.　　

     5. 100%duty cycle ,continuous working ability at maximum power.　　

     6. Constant power or constant voltage control mode.

     7. Display of output power,output frequency,and output voltage.

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±20%	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-6KW-I		6.0KW	28A
	DW-UHF-6KW-II		6.0KW	28A
	DW-UHF-6KW-III		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-6, 0KW		60KW	90A	50-150KHZ

Induction_heating_catalogue.pdf

Brazing Wire to Copper Bar With Induction

Brazing Wire to Copper Bar With Induction Objective: To heat a compacted litz wire bundle for wire stripping then braze the litz wire bundle to a copper block for use in an automotive motor. Material: Compacted litz wire bundle 0.388” (9.85mm) wide, 0.08” (2.03mm) thick copper bar 0.5” (12.7mm) wide, 0.125” (3.17mm) thick and 1.5” (38.1mm) long braze wire & white flux Temperature 1400 ºF (760 ºC) Frequency 300 kHz Equipment • DW-UHF-10 kW 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 three turn helical coil is used for the wire stripping process.The litz wire bundle is placed in the coil for 3 seconds to strip the lacquer 0.75” (19mm) from the end of the bundle. The wire bundle is then scraped with a metal brush to remove the burnt lacquer. For the brazing process a two turn channel coil is used. The litz wire and copper assembly are placed in the coil and the braze wire is fed by hand. The braze is completed in 45-60 seconds. Results/Benefits Induction heating provides: • Consistent, repeatable results • Faster process time, increased production • Even distribution of heating

Induction Brazing Stainless Steel

Induction Brazing Stainless Steel Objective 1st Application: Braze hub assembly to needle holder 2nd Application: Braze Large tube to ring joint Material: 1st Application: Steel hub assembly and needle 0.1" dia(2.5mm) 2nd Application: Steel tube 1" OD (25.4 mm) and ring Temperature 1400 ºF (760 ºC) Frequency 325 kHz for brazing the needle 0.1" dia (2.5mm) 259 kHz for brazing ring to steel tube 1" OD (25.4 mm) Equipment • DW-UHF-4.5KW induction heating system, equipped with a remote workhead containing two .66 μF capacitors for a total of 1.32 μF • Two induction heating coils, designed and developed specifically for this dual application. Process 1st application: A two-turn helical coil is used to heat the hub assembly on the needle holder for 10 seconds. The coil concentrates the heat on the hub only, as the needle is magnetic and the hub material is non-magnetic. A small diameter braze wire is used to supply sufficient amount of braze creating a strong aesthetically pleasing bond. 2nd application: A three-turn helical coil is used for brazing the large tube to the ring joint for 3-5 minutes. A braze ring is used to supply sufficient amount of braze to create an aesthetically pleasing bond. Results/Benefits Induction heating provides: • Even distribution of heating, provides even flow of braze alloy for an aesthetically pleasing bond • System flexibility allows for the same unit to be used for two different applications which is a cost saving. https://dw-inductionheater.com/induction-brazing-stainless-steel.html?feed_id=229866&_unique_id=653f3ad01cccf

Annealing Metal Stamp With Induction

Annealing Metal Stamp With Induction Objective: Induction Heating the opposite end of a metal stamp so that it mushrooms instead of cracks/splits when struck by a hammer. Material S-7 steel of varying rectangular cross sectional sizes Temperature 1400-1800 ºF (760-982) ºC Frequency 300 kHz Equipment DW-UHF-10KW, induction heating system, equipped with a remote heat station containing two 1.5 μF capacitors for a total of 0.75 μF and three different induction heating coils designed and developed specifically for this application. Process One five-turn and two four-turn helical coils are used to heat the end of stamps to the required temperature. Two part sizes can be run in each of coils, using the same machine settings except for cycle time. Cycle rates dependent upon the crosssection size. The 3/8" (0.9525 cm) square size is has a rate of below 10 seconds. The rate for the middle size, ½" – 1 ½ " (1.27 - 3.81 cm) is 30 to 60 seconds. A 1" (2.54 cm) square part takes approximately two minutes. Fixturing can influence the length of the cycle time required. For shorter heat times a larger power supply may be used. Results/Benefits Precise heat only to the area that needs annealing is more efficient and repeatable than heating with a torch.  

Induction Brazing & Soldering Principle

Induction Brazing & Soldering Principle Brazing and soldering are processes of joining similar or dissimilar materials using a compatible a filler material. Filler metals include lead, tin, copper, silver, nickel and their alloys. Only the alloy melts and solidifies during these processes to join the work piece base materials. The filler metal is pulled into the joint by capillary action. Soldering processes are conducted below 840°F (450°C) while brazing applications are conducted at temperatures above 840°F (450°C) up to 2100°F (1150°C). The success of these processes depends upon the assembly's design, clearance between the surfaces to be joined, cleanliness, process control and the correct selection of equipment needed to perform a repeatable process. Cleanliness is ordinarily obtained by introducing a flux which covers and dissolves dirt or oxides displacing them from the braze joint. Many operations are now conducted in a controlled atmosphere with a blanket of inert gas or combination of inert / active gasses to shield the operation and eliminate the need for a flux. These methods have been proven on a wide variety of material and part configurations replacing or complimenting atmosphere furnace technology with a just in time - single piece flow process. Brazing Filler Materials Brazing filler metals can come in a variety of forms, shapes, sizes and alloys depending on their intended use. Ribbon, preformed rings, paste, wire and preformed washers are just a few of the shapes and forms alloys that can be found. The decision to use a particular alloy and/or shape is largely dependent on the parent materials to be joined, placement during processing and the service environment for which the final product is intended. https://dw-inductionheater.com/induction-brazing-soldering-principle.html?feed_id=229836&_unique_id=653e83fe79f02

Ultrasonic Welding Machine | Ultrasonic plastic Welder For Bonding Solutions

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. Ultrasonic Welding Horns/Ultrasonic Welding Molds: 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 sealing glass

Induction sealing glass to enclose resistors with high frequency induction heating system Objective Provide a hermetic seal of glass enclosed resistor to a lead Material Resistor Kovar rings, 0.1 inch (0.254cm) diameter Glass tube slightly larger than 0.1 inch (0.254cm) diameter, 0.5 (1.27) inch length Metal lead Temperature 900 ºF (482) ºC Frequency 324 kHz Equipment • DW-UHF-6kW-III induction heating system, equipped with a remote workhead containing two (2) 1.5 μF capacitors (for a total of 0.75 μF). • An induction heating coil designed and developed specifically for this application. Process A three turn concentrator plate coil is used to heat the Kovar ring for 500 milliseconds. This causes the glass to melt and seal one side of the resistor. The resistor is then turned over and the process is repeated to seal the other side using a second Kovar ring. Results/Benefits Induction heating provides precise, consistent heat to very small parts resulting in repeatable, quality seals. By heating with medium frequency, arcing (which occurs at high frequencies) is avoided.  

Brazing Carbide To Steel Shank

Brazing Carbide To Steel Shank with Induction Objective :Brazing carbide teeth to a steel jaw in less than 5 minutes Material: Steel pipe jaw, 0.5” (12.7mm) dia, 1.25” (31.75mm) long, 0.25”(6.35mm) thick carbide teeth, black flux and silver copper braze shims Temperature: 1292ºF (700ºC) Frequency: 300kHz Equipment • DW-UHF-10kW 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 rectangular helical coil is used to heat the carbide and steel to 1292ºF (700ºC) for 4 to 5 minutes. Three braze shims control the amount of braze and the even heat allows for a good flow of braze creating an aesthetically pleasing bond. Results/Benefits Induction heating provides: • Hands-free heating that involves no operator skill for manufacturing • Consistent, repeatable aesthetically pleasing brazes • Even distribution of heating https://dw-inductionheater.com/brazing-carbide-to-steel-shank.html?feed_id=229806&_unique_id=653dcd6ce2c3a

induction heating medical and dental applications

Induction heating medical and dental applications-induction heating systems for medical and dental industry

Induction heating is widely used within the medical and dental industries. Manufacturers of medical equipment benefit from induction heating technology. It provides clean, concise, repeatability, and is environmentally safe due to no open flame or toxic emissions. It is used in small laboratories as well as large production facilities. In recent years more and more medical research institutions are using induction heating for nanoparticle and electromagnetic hyperthermia treatment research. HLQ DW-UHF induction heating equipment is designed specifically with this application in mind. HLQ induction heating systems are used in many Universities and Research facilities around the world. How Induction Heating is used in the Medical & Dental Industries?

• Nanoparticle and hyperthermia treatment research and testing
• Induction casting of dentures and medical implants
• Catheter tipping to form the tips of medical catheters
• Sterilizing of connections in pharmaceutical or biomedical manufacturing
• Heat treatment of memory alloys for medical applications
• Needle and surgical instruments heat treating and heat staking
• Medication or blood plasma heating for IV devices

Induction Heating systems are used in many processes within the Medical industries. The type of Induction heating applications you will find are catheter tip forming, dental drill bit brazing, plastic to metal bonding and many more.

There are many benefits to using Induction Heating within the Medical industry. The benefits are a very clean non contact heating process which is energy efficient and an extremely reputable heating process. Induction heating is a very fast way of heating your components in a consolable way. This will help improve your production throughput and improve Quality.

Induction coil solutions has many years of knowledge within the Medical industry supporting customers with new development work and helping with new coil designs for the new components. Induction coil Solutions has also helped many blue-chip companies with keeping they’re production lines running either with new replacement Induction Heating coils, or repaired Induction Heating Coils.

Medical and Dental Device Manufacturing Solutions

In today’s increasingly competitive global economy, medical device manufacturing companies are continually seeking ways to drive down production costs and accelerate time-to market. At the same time, improved product quality and manufacturing consistency are absolutely essential; there can be no shortcuts when a patient's life and well-being are at stake. Medical device manufacturers turn to advanced induction heating technology to help meet their production, cost and quality goals. Induction heating is a quick, clean, non-contact method of inducing heat for a wide variety of metal joining and heat treating applications . When compared to convection, radiant, open flame or other heating methods, induction heating offers substantial advantages.

• Increased consistency with solid state temperature control & closed loop monitoring systems
• Maximized productivity with in-cell operation; no soaking time or lengthy cool down cycles
• Improved quality with minimized product warpage, distortion and reject rates
• Extended fixture life with site-specific heat without heating any surrounding parts
• Environmentally sound without flame, smoke, waste heat, noxious emissions or loud noise
• Reduced energy consumption with up to 80% energy efficient operation

Among the many medical device manufacturing applications for induction heating: Annealing Incoloy Tubing In A Protective Atmosphere  With a 20kW power supply, induction heating can be used to heat steel tubing to 2000°F for annealing at a rate of 1.4 inches per second. Brazing Steel Orthodontic Parts  For this application we utilized an inert atmosphere to braze batches of orthodontic parts at 1300°F within 1 second Heat Setting Nitinol Medical Subtends  Induction heating was used to heat set medical stents on a mandrel to set proper size in two minutes at 510°C Brazing Three Joint Areas On A Dental Prophy Jet   With the right induction heating coil design, it is possible to braze three joints at once. In ten seconds, three joints on a dental prophy jet assembly were heated to 1400°F for brazing with improved yield consistency and reduced cycle time. Heat Staking A Threaded Brass Electrical Connector Into A Plastic Shell   Consistent, repeatable results were achieved at 500°F with a 10 second heat cycle. The electrical connector was firmly bonded to the plastic shell without any flashing or discoloration.

Brazing Automotive Parts With Induction

Brazing Automotive Parts With Induction Objective: To braze a automotive steel tube to a steel “T” fitting Material 1” (25.4mm) diameter steel tubing, steel fitting, braze slug and black flux Temperature 1400ºF (760ºC) Frequency 200 kHz Equipment • DW-UHF-10 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 four turn split helical coil is used to heat the steel assembly to 1400ºF (760ºC) for 85 seconds. The coil design allows for the steel fitting to expand away from the steel tube which allows braze to flow through the joint. The amount of braze alloy is controlled by the braze slug allowing for an aesthetically pleasing joint. Results/Benefits Induction heating provides: • Hands-free heating that involves no operator skill for manufacturing • Precise and uniform distribution of heating • The collection of flux on the coil is reduced due to efficient coil design. https://dw-inductionheater.com/brazing-automotive-parts-with-induction.html?feed_id=229776&_unique_id=653d1667dc9ae

induction Brazing copper rods to brass strips

Objective Induction Brazing copper rods to brass strips to replace torch operation. The current torch process results in excessive contaminants on the assembly, and requires extensive rework after the induction brazing operation.

Equipment DW-UHF-10KW INDUCTION BRAZING MACHINE Two turn open end conveyor coil Materials • Copper coupon plate and copper rod • Braze wire – EZ Flo 45 • Braze alloy – 45% Silver, 1/32 DIA

Key Parameters – TEST 1 Power: 7.2 kW Temperature: Approximately 1350° F (732° C) Time: Average time – 100 seconds Process and Results: For Induction brazing copper plate to copper rod,, EZ Flo 45 braze wire was cut into 2” lengths and placed in the interface area. In a production situation, EZ Flo 45 brazing paste is recommended. The assemblies were set up and heated for an average time of 100 seconds to flow the alloy and achieve the braze.

Key Parameters – TEST 1 Power: 6 kW Temperature: Approximately 1350° F (732° C) Time: Average time – 2.5 minutes Process and Results: For Induction brazing copper rod to brass plate,, EZ Flo 45 braze wire was cut into 2” lengths and placed in the interface area. In a production situation, EZ Flo 45 brazing paste is recommended. The assemblies were set up (see photographs) and heated for an average time of 2.5 minutes to flow the alloy and achieve the braze. Due to the metal resistance differential between copper and brass, the brass bar heat preferentially. The induction heating coil designed to braze the bars to the plate section heats the rods and the heat is transferred to the plate more by conduction than induction causing the bars to initially reach temperature prior to the plate. If the materials are the same (cooper to copper or brass to brass, this is not a problem. If the bar is copper and the plate is brass there are not issues – only when the bar is brass and the plate is copper. This requires the power to be reduced to allow tie for heat transfer from the brass rod to the copper plate.

Key Parameters – TEST 1 Power: 7.2 kW Temperature: Approximately 1350° F (732° C) Time: Average time – 2 minutes Process and Results: For Induction braze copper coupon plate and copper rod,, EZ Flo 45 braze wire was cut into 2” lengths and placed in the interface area. In a production situation, EZ Flo 45 brazing paste is recommended. The assemblies were set up  and heated for an average time of 2 minutes to flow the alloy and achieve the braze.

Results/Benefits:

• induction brazing Strong durable joints
• Selective and precise heat zone, resulting in less part distortion and joint stress than welding
• Less oxidation
• Faster heating cycles
• More consistent results and suitability for large volume production, without the need for batch processing
• Safer than flame brazing

Brazing Cutting Tool with Induction

Brazing Cutting Tools with Induction Objective: To braze cone and shaft for a cutting tool Material Customer supplied parts Temperature indicating paint Braze preforms Temperature 1300 - 1400 ºF (704 – 760 °C) Frequency 400 kHz Equipment: DW-UHF-6kw-I, 250-600 kHz induction heating system, including remote heat station using two 0.66 μF capacitors (total 1.32 μF) A two-position, two-turn induction heating coil designed and developed specifically for this application. Process: Two sets of parts are placed in the individual coils. Braze preforms are placed on the cone at the joint. The assembled part is placed inside the induction heating coil and heated until the braze melts. Results/Benefits: efficient coil design enables simultaneous heating of two parts on the single 2kW system. dual braze is accomplished within required process time, increasing process throughput

Brazing Golf Ball With Induction

Brazing Golf Ball With Induction Objective: Heating steel golf ball mold to brazing dimple insert Material: Golf ball mold 2” in diameter, braze flux paste, dimple insert Temperature: 1400 ºF (760 ºC) Frequency: 260 kHz Equipment • DW-UHF-10kW induction heating system, equipped with a remote workhead containing two 0.5μF capacitors for a total of 0.25 μF • An induction heating coil designed and developed specifically for this application. Process A four turn helical coil is used to heat the golf ball mold to 1400ºF (760 ºC) in 3 minutes and the dimple insert is brazed to the mold with braze flux paste. Results/Benefits Induction heating provides: • No flame process. • Reliable, repeatable, non contact and energy efficient heat in minimal time. • Even distribution of heating. https://dw-inductionheater.com/brazing-golf-ball-with-induction.html?feed_id=229716&_unique_id=653ba8d7d30e9

Induction Heating fundamentals PDF

Induction heating fundamentals physical principles

Characteristics of induction heating • High temperature in the workpiece (in most cases). • High power density for a short heating time (in many applications). • High frequency (in many applications). • Thermal sources are inside the workpiece. Induction Heating fundamentals Induction-Heating-fundamentals.pdf

Induction Brazing Copper T Pipe With Induction Heating Machine

Objective Evaluate replacing of flame copper t pipe brazing with induction brazing. Equipment DW-HF-25kw high frequency induction heating machine

Materials

• Copper main tube – 1.13” (28.7 0mm) OD 1.01” (25.65 mm) ID • Riser tube copper – 0.84” (21.33 0mm)  OD,  0.76” (19.30 0mm)  ID Power: Power manually reduced from max output of 10kW to 15kW to provide even heat distribution on the assembly with the modified test coil. NOTE: Heat time can be improved with custom coil design. Temperature:  Approximately 704° C (1300° F) Time: 25sec

Process Steps: The copper tubes were cleaned and assembled. Two preformed alloy rings were made from available alloy in lab for the demonstration.  The wire used measured 0.787mm (0.031”) in diameter  Both the riser an base copper tubes were pre-fluxed with white braze flux. The assembly was placed in the test coil per the video bellow and the alloy flowed to form a joint at the “T” interface in 30seconds. Results and Conclusions: The target heat time for the smallest T joint assembly is 20 seconds . Using a lab test coil, we were able to effect a braze in the interface section of the tubes (copper) in 30 seconds.  

 

Induction Brazing Stainless Steel

Induction Brazing Stainless Steel Car grill  Objective Braze an end plug on a stainless steel car grill before powder coating application Material Stainless steel car grill 0.5” x 0.19” (12.7mm x 4.8mm), end plugs and braze ring Temperature: 1350 ºF (732°C) Frequency:400 kHz Equipment •DW-UHF-6kW-III 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 three turn square shaped helical coil is used to heat the end of the grill. End plugs are inserted into the grill and the assembly is inserted into the coil for 30 seconds. The braze flows to create a neat and clean leak-proof joint. Results/Benefits Induction heating provides: • Rapid localized heat to joint area only • Minimized oxidation reduces cleaning time • Hands-free heating that involves no operator skill for manufacturing • Even distribution of heating https://dw-inductionheater.com/induction-brazing-stainless-steel-car-grill.html?feed_id=229656&_unique_id=653a3b7a10417

Aluminum Scrap Melting Recycling Induction Furnace

The top 200^1500kg Induction Aluminum Scrap Melting Recycling Induction Furnace for recycling and melting aluminum scraps,ingots,cans and dross material.

Operation Steps:

• An Aluminum scraps/ingots/cans recycling furnace operator will place aluminum parts or aluminum ingot/scrap as a charge in the induction melting aluminum recycling furnace and start the furnace to begin the melting process. Adding more aluminum charge this process is advisable as molten aluminum transmits the heat better.
• When temperature of the aluminum reaches 1220.66°F it turns to liquid. Any residue from the coating and paint from the cans will float on the surface. This byproduct is called dross and can be skimmed by a steel ladle. This needs to cool before it can be disposed off safely.
• Next, the crucible (furnace) will pour out pure aluminum. Usually, Hydraulic tilting mechanism provided to pour large quantities of liquid metals.
• Finally, with care, the molten aluminum will be poured into mould to cool down and then slide out for use.

Advantages of Aluminum Scrap Melting Recycling Induction Furnace: 1, save energy and reduce the environmental temperature Original diesel furnace workshop on pollution, but also the auxiliary exhaust pipeline, inside and outside the furnace heat has a large number of distribution in the workshop, resulting in high temperature workshop. So is the original furnace condition, most escapes to the air, there is heat conduction loss, the production of large power consumption, increase the cost of production. At the same time, the ambient temperature increases. The electromagnetic induction heating process, the heating element is through magnetic field heating, in order to reduce the loss of heat conduction, fast heating, melting rapidly, thus reducing energy consumption. Reduce electricity consumption. After the comparison of the experimental test and modification, the power saving effect is 20%-40%. 2, rapid heating, temperature control accurate real-time Electromagnetic induction heating method is through the magnetic field lines make heating rapid heating, the rapid melting Aluminum Alloy. The temperature control is real-time and accurate, which improves the quality of the product and improves the production efficiency! 3 and long service life, simple maintenance The traditional electric melting induction furnace heating method is to use resistance wire heating, resistance wire in the high temperature environment for a long time in the use of oxidation will result in reducing its service life, high maintenance costs. The electromagnetic heating coil is made of insulating material and high temperature wire, so the service life is long and without any maintenance. 4, power Electromagnetic induction heating with the development and maturity of the technology, the production process and technology of components, software, such as reliable protection of the current power can be 2-200KW. 5, safe The utility model adopts the electromagnetic induction heating, which can reduce the surface temperature of the machine, and the human body can be safely touched, so as to avoid the occurrence of burn and scald accidents caused by the traditional heating mode and protect the production safety of the employees. Features 1 energy saving and environmental protection, Germany's IGBT power devices, high reliability, stable operation and low maintenance costs. 2) the frequency of the digital phase locked loop tracking, automatic load impedance matching. 3 power closed-loop control, to avoid the temperature change caused by the power down. 4) over voltage, under voltage, lack of phase, over current, over heat protection, real-time display of the parameters, fault diagnosis and alarm; leakage automatic alarm, cut off the power supply and the working state of real-time display. 5) PID heating control system, uniform heating temperature, prevent molten aluminum temperature drift, burning less, homogeneous metal components to improve the product qualification rate. 6 (LED) digital temperature controller, measuring and controlling the temperature accuracy of up to 3 degrees centigrade, the quality of aluminum soup is good, the melting temperature rises quickly, the furnace temperature is easy to control, the production efficiency is high; 7) the integral structure of polycrystalline mullite fibers of furnace, small volume, good insulation property, low energy consumption, high efficiency, temperature above 1200 degrees, long service life; 8. The operation is simple and the power can be adjusted with the work; 9 (100%) load duration, maximum power, to ensure the operation of 24 hours. Melting capacity of SMJD series Aluminum Scrap Melting Recycling Induction Furnace:   

Type	Input Power	Melting Capacity			Max Temperature
		steel, stainless steel	copper, gold, silver (scrap, Slag)	aluminum, aluminum alloy, Aluminum scrap, Aluminum slag, pop can	1800℃
SMJD-463	60 KW	200 KG	500 KG	200 KG
SMJD-480	60 KW	150 KG	500 KG	150 KG
SMJD-580	80 KW	200 KG	600 KG	200 KG
SMJD-600	60 KW	230 KG	560 KG	230 KG
SMJD-900	120 KW	300 KG	900 KG	300 KG
SMJD-905	80 KW	300 KG	900 KG	300 KG
SMJD-1250	80 KW	400 KG	1200 KG	400 KG
SMJD-1250	120 KW	450 KG	1350 KG	450 KG
SMJD-1500	120 KW	500 KG	1500 KG	500 KG
SMJD-1550	120 KW	520 KG	1560 KG	520 KG
SMJD-1700	160KW	600 KG	1700 KG	600 KG
SMJD-2300	160KW	800 KG	2000 KG	800 KG
SMJD-3100	200KW	1200 KG	3000 KG	1200 KG

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Brazing Silver To Copper With Induction

Brazing Silver To Copper With Induction  Objective: Heat silver contacts and brass/copper bus for brazing application Material: Silver contact .75 (19mm) diameter, brass and copper bus 2” x 1” (50.8 x 25.4mm), braze shims, white flux Temperature 1300 ºF (704 ºC) Frequency 300 kHz Equipment • DW-UHF-10kW 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 five turn split helical coil is used to heat the assembly. The parts are placed 90º to the coil between the top turn and second turn with braze shims and flux. The parts reach 1300ºF (704 ºC) in less than 40 seconds to braze the parts together. Results/Benefits Induction heating provides: • Hands-free heating that involves no operator skill for manufacturing • Better joint quality • Faster heating cycles, more consistent results • Even distribution of heating

Brazing Stainless Steel To Copper With Induction

Brazing Stainless Steel To Copper With Induction  Heater Objective Braze a stainless steel braided hose to copper elbows for a braided hose assembly. Material Stainless steel braided hose 3/8” (9.5mm) OD, copper elbow 1/4” (6.3mm) OD, braze preform rings and black flux Temperature 1400 ºF (760 ºC) Frequency 300 kHz Equipment • DW-UHF-6kW-III 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 two turn helical coil is used to heat the braided hose assembly. Braze rings are placed at the joint on the copper elbow and flux is applied to the entire surface of the assembly. The assembly is placed in the heating coil and the braze flows within 30-45 seconds. This creates a liquid and gas tight braze between the copper and stainless steel braided hose. Results/Benefits Induction heating provides: • Liquid and gas-tight braze • Energy efficient heat in a minimal amount of time • Controllable braze flow through the use of braze rings • Even distribution of heating https://dw-inductionheater.com/brazing-stainless-steel-to-copper-with-induction.html?feed_id=229626&_unique_id=653984782f7fa