induction brazing copper and brass rods

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

Equipment DW-UHF-40KW high frequency 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 TEST Power: 30 kW Temperature: Approximately 1350° F (732° C) Time: Average time – 25 seconds 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 (see photographs) and heated for an average time of 25s to flow the alloy and achieve the braze. Due to the metal resistance differential between copper and brass, the brass bar heat preferentially. The 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. Results/Benefits:

• 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

   

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Induction Brazing copper to copper pipes

High Frequency Induction Brazing copper to copper pipes Process

Objective: Induction Brazing copper to copper pipes Equipment: DW-UHF-6KW-III handheld induction brazing heater Materials:  Six Copper pipes (9.5 mm) Power: 6 kW Temperature: 1475 °F/ 800°C Time: 20 seconds

Process: The DW-UHF-6KW-III handheld induction brazing system with robot can automatically induction braze multiple joints located in predefined positions. For this brazing application a wire feeder was mounted to the DW-UHF-6KW-III induction brazing heater, which feds the alloy onto the copper joints. A nitrogen nozzle was also added to reduce oxidization of the joints, this helps minimize the brazed joints cleaning procedure. The robotic system is programmed to move to each joint and apply power for a pre-programmed amount of time. This ensures a repeatable and reliable brazing process. The induction brazing of copper to copper was performed successfully within 20 seconds per joint at 1475 °F. The DW-UHF-6KW-III handheld induction brazing heater is ideal for flameless brazing of refrigerator compressors, heat exchangers, home appliance components and complex HVAC assemblies.

https://dw-inductionheater.com/induction-brazing-copper-to-copper-pipes.html?feed_id=238262&_unique_id=6600c16a2964f

induction brazing stainless steel to copper

Objective Induction Brazing stainless steel to copper tubing. Objective is to evaluate induction brazing solution. Customer is looking to reduce defects and for a cleaner brazing environment. Due to different pipe size and lower volume – evaluation is performed with a induction brazing system.

Test1 Equipment DW-HF-25kw induction brazing machine Materials Copper to Stainless steel tube Power: 12.5kW Temperature: 1400ºF to 1600ºF (760ºC to 871ºC) Time: 9 to 11 seconds

Test2 Equipment DW-HF-25kw induction brazing machine Materials Copper to Stainless steel Power: 12.5kW Temperature: 1400ºF to 1600ºF (760ºC to 871ºC) Time: 9 to 11 seconds

Results and Conclusions: Induction brazing test with U open coil was able to braze the parts in 9 to 11 seconds for the full braze cycle. Operator training with this setup will be minimal.

https://dw-inductionheater.com/induction-brazing-stainless-steel-to-copper.html?feed_id=237489&_unique_id=65fa5452b9bfb

Induction Brazing Copper To Copper Parts

Objective Induction Brazing Copper to Copper parts Spacer. The workpieces were heated to 2012˚F (1100˚C) in 1 minutes. Recommended Equipment The recommended equipment for this application is the  DW-HF-45kw induction heating machine

Materials:

• Copper section: 0.55” thick x 1.97” long x 1.18” wide x 0.2” long (14 mm thick & 50 mm long x 30 mm wide x 5 mm long)
• Copper spacer: 0.55” thick x 1.57” long x 0.79” wide x 0.08” long (14 mm thick & 40 mm long x 20 mm wide x 2 mm long)
• Brazing alloy: 5% silver brazing rod

Power: induction heating power supplies up to 30 kW Temperature: 2012˚F (1100˚C) Time: 1 minutes

https://dw-inductionheater.com/induction-brazing-copper-to-copper-parts.html?feed_id=237421&_unique_id=65f99d587a9e5

Induction Brazing Copper Lap Joints: A Reliable and Efficient Joining Method

Induction Brazing Copper Lap Joints: A Reliable and Efficient Joining Method

Induction brazing copper lap joints is a highly effective method for joining copper components with precision and strength. The process involves using an induction heating system to generate heat directly within the copper material, allowing for a localized and controlled heating of the joint area. The brazing filler metal, typically a copper-based alloy, is then introduced to the heated joint, melting and flowing into the gap to create a strong, durable bond. Induction brazing offers several benefits including rapid heating, minimal distortion, and the ability to join dissimilar metals. If you are looking for a reliable and efficient method to braze copper lap joints, induction brazing is the way to go. 1. The Advantages of Induction Brazing Copper Lap Joints 1.1. Precise Heat Control: Induction brazing allows for precise and localized heating, minimizing the risk of thermal damage to the surrounding areas. This is especially important when working with sensitive copper components or assemblies with complex geometries. 1.2. Increased Efficiency: Induction heating is fast and efficient, as it directly heats the workpiece without the need for preheating the entire assembly. This results in reduced energy consumption, shorter cycle times, and increased productivity. 1.3. Stronger Joints: Induction brazing produces high-quality joints with excellent bond strength. The controlled heating process ensures uniform heating and proper filler metal flow, resulting in robust and reliable connections. 1.4. Clean and Environmentally Friendly: Induction brazing eliminates the need for open flames or torches, minimizing the risk of contamination and creating a safer working environment. Additionally, it reduces the generation of harmful fumes and pollutants, making it an eco-friendly choice. 2. The Induction Brazing Process for Copper Lap Joints 2.1. Preparation: Thoroughly clean the copper surfaces to remove any contaminants, such as dirt, grease, or oxide layers. This ensures optimal bonding and prevents defects in the joint. 2.2. Filler Metal Selection: Choose a brazing filler metal that is compatible with copper and suitable for your specific application. Silver-based alloys, such as silver-copper-phosphorus, or copper-phosphorus alloys are commonly used for copper brazing. 2.3. Joint Assembly: Position the copper parts in a lap joint configuration, ensuring a close fit. Fixtures or clamps can be used to secure the parts during the brazing process. 2.4. Flux Application: Apply a suitable flux to the joint area. The flux removes oxide layers, promotes wetting of the filler metal, and prevents oxidation during heating. Select a flux specifically formulated for brazing copper. 2.5. Induction Heating: Position the copper assembly within the induction coil, ensuring the joint area is within the heating zone. Adjust the induction heating system's power, frequency, and parameters based on manufacturer guidelines and the size/thickness of the copper parts. 2.6. Filler Metal Introduction: Once the joint area reaches the brazing temperature, introduce the filler metal. It can be in the form of a pre-placed filler wire or applied directly as a brazing paste or powder. The heat from the induction process melts the filler metal, allowing it to flow into the joint. 2.7. Cooling and Cleaning: After the filler metal has completely filled the joint, switch off the power and allow the joint to cool naturally. Once cooled, remove any residual flux or oxide from the brazed joint using appropriate cleaning methods. 3. Applications of Induction Brazing Copper Lap Joints 3.1. Electrical and Electronics Industry: Induction brazing is widely used in manufacturing electrical connectors, motor windings, transformers, and various electronic components that require reliable electrical conductivity and mechanical strength. 3.2. HVAC and Refrigeration: Copper tube connections in air conditioning, refrigeration, and heat exchanger systems often employ induction brazing for its efficiency, accuracy, and consistent quality. 3.3. Automotive and Aerospace: Induction brazing is utilized in the production of automotive heat exchangers, fuel systems, and aerospace components, ensuring reliable performance under demanding conditions. 3.4. Plumbing and Pipe Fittings: Copper plumbing fittings, valves, and pipe joints can be efficiently and effectively brazed using induction, providing leak-free connections and extended service life. Conclusion Induction brazing copper lap joints is a highly efficient and effective method of joining two copper pieces together. The process involves using an induction heating system to heat the joint area, melting a filler metal, and creating a strong bond between the copper pieces. This technique offers several advantages, including precise and localized heating, minimal distortion, and faster heating cycles. Induction brazing also ensures a clean and contamination-free joint, resulting in superior quality and strength. Whether you require brazing for plumbing, electronics, or any other copper applications, our skilled technicians are ready to provide reliable and durable solutions. Trust our expertise in induction brazing copper lap joints for a seamless and robust joining process that meets your specific needs. https://dw-inductionheater.com/induction-brazing-copper-lap-joints-a-reliable-and-efficient-joining-method.html?feed_id=231466&_unique_id=65967e5a9fb68

Induction Brazing Copper Lap Joints: A Reliable and Efficient Joining Method

Induction Brazing Copper Lap Joints: A Reliable and Efficient Joining Method

Induction brazing copper lap joints is a highly effective method for joining copper components with precision and strength. The process involves using an induction heating system to generate heat directly within the copper material, allowing for a localized and controlled heating of the joint area. The brazing filler metal, typically a copper-based alloy, is then introduced to the heated joint, melting and flowing into the gap to create a strong, durable bond. Induction brazing offers several benefits including rapid heating, minimal distortion, and the ability to join dissimilar metals. If you are looking for a reliable and efficient method to braze copper lap joints, induction brazing is the way to go. 1. The Advantages of Induction Brazing Copper Lap Joints 1.1. Precise Heat Control: Induction brazing allows for precise and localized heating, minimizing the risk of thermal damage to the surrounding areas. This is especially important when working with sensitive copper components or assemblies with complex geometries. 1.2. Increased Efficiency: Induction heating is fast and efficient, as it directly heats the workpiece without the need for preheating the entire assembly. This results in reduced energy consumption, shorter cycle times, and increased productivity. 1.3. Stronger Joints: Induction brazing produces high-quality joints with excellent bond strength. The controlled heating process ensures uniform heating and proper filler metal flow, resulting in robust and reliable connections. 1.4. Clean and Environmentally Friendly: Induction brazing eliminates the need for open flames or torches, minimizing the risk of contamination and creating a safer working environment. Additionally, it reduces the generation of harmful fumes and pollutants, making it an eco-friendly choice. 2. The Induction Brazing Process for Copper Lap Joints 2.1. Preparation: Thoroughly clean the copper surfaces to remove any contaminants, such as dirt, grease, or oxide layers. This ensures optimal bonding and prevents defects in the joint. 2.2. Filler Metal Selection: Choose a brazing filler metal that is compatible with copper and suitable for your specific application. Silver-based alloys, such as silver-copper-phosphorus, or copper-phosphorus alloys are commonly used for copper brazing. 2.3. Joint Assembly: Position the copper parts in a lap joint configuration, ensuring a close fit. Fixtures or clamps can be used to secure the parts during the brazing process. 2.4. Flux Application: Apply a suitable flux to the joint area. The flux removes oxide layers, promotes wetting of the filler metal, and prevents oxidation during heating. Select a flux specifically formulated for brazing copper. 2.5. Induction Heating: Position the copper assembly within the induction coil, ensuring the joint area is within the heating zone. Adjust the induction heating system's power, frequency, and parameters based on manufacturer guidelines and the size/thickness of the copper parts. 2.6. Filler Metal Introduction: Once the joint area reaches the brazing temperature, introduce the filler metal. It can be in the form of a pre-placed filler wire or applied directly as a brazing paste or powder. The heat from the induction process melts the filler metal, allowing it to flow into the joint. 2.7. Cooling and Cleaning: After the filler metal has completely filled the joint, switch off the power and allow the joint to cool naturally. Once cooled, remove any residual flux or oxide from the brazed joint using appropriate cleaning methods. 3. Applications of Induction Brazing Copper Lap Joints 3.1. Electrical and Electronics Industry: Induction brazing is widely used in manufacturing electrical connectors, motor windings, transformers, and various electronic components that require reliable electrical conductivity and mechanical strength. 3.2. HVAC and Refrigeration: Copper tube connections in air conditioning, refrigeration, and heat exchanger systems often employ induction brazing for its efficiency, accuracy, and consistent quality. 3.3. Automotive and Aerospace: Induction brazing is utilized in the production of automotive heat exchangers, fuel systems, and aerospace components, ensuring reliable performance under demanding conditions. 3.4. Plumbing and Pipe Fittings: Copper plumbing fittings, valves, and pipe joints can be efficiently and effectively brazed using induction, providing leak-free connections and extended service life. Conclusion Induction brazing copper lap joints is a highly efficient and effective method of joining two copper pieces together. The process involves using an induction heating system to heat the joint area, melting a filler metal, and creating a strong bond between the copper pieces. This technique offers several advantages, including precise and localized heating, minimal distortion, and faster heating cycles. Induction brazing also ensures a clean and contamination-free joint, resulting in superior quality and strength. Whether you require brazing for plumbing, electronics, or any other copper applications, our skilled technicians are ready to provide reliable and durable solutions. Trust our expertise in induction brazing copper lap joints for a seamless and robust joining process that meets your specific needs. https://dw-inductionheater.com/induction-brazing-copper-lap-joints-a-reliable-and-efficient-joining-method.html?feed_id=231466&_unique_id=65965a2acdca1

Brazing Copper Tube with Induction

Brazing Copper Tube with Induction Objective: To braze a copper tube ( 3/8" OD by 2-4" long) into a 3/8" fitting in less than 10 seconds. Heating must take place in a channel type coil to allow for easy loading of parts. Material Copper Tubing and Fitting with Braze and Stay Silv White Flux Temperature 1300°F Frequency 215 kHz Equipment DW-UHF-10kw output solid state induction power supply equipped with a standard heat station containing eight 0.33 μF capacitors for a total of 0.66μF, a step down transformer, and a specifically designed induction heating coil. Process DW-UHF-10kw solid state induction power supply was setup to achieve the following results: · 2.0 kW of power was directly loaded into the copper tube resulting in a heating time of 7.2 seconds to reach the necessary 13000F for brazing. Results& Processing ease was achieved through the design of a unique channel type coil comprised of three turns of 1/8" copper. https://dw-inductionheater.com/brazing-copper-tube-with-induction.html?feed_id=230646&_unique_id=6551cbf8aabdc

Brazing Copper Tube to Brass Fitting With Induction

Brazing Copper Tube to Brass Fitting With Induction  Objective: To use induction heating to braze a copper tube to a brass fitting using a preform braze wire. Processing is to occur under an atmosphere of Nitrogen and 4% Hydrogen gas. The braze preforms melt at 1190°F, but the parts need to be kept below 1300°F. The parts need to be processed at a rate of 175 to 200 per hour which translates into 18 seconds of heating time per part. Material Copper Tubing Measuring 0.5" OD and 2" Long, Brass fitting, Braze Preform, No Flux. Temperature Above 1190°F but not to exceed 1300°F Frequency :300 kHz Equipment: DW-UHF-10KW output solid state induction heating power supply with three (3) busses, eight (8) capacitors totaling 0.66 μF, and a unique four turn helical coil. Process The DW-UHF-10KW output solid state power supply along with a unique four turn helical coil were used to achieve the following results. Results • The requested atmosphere was provided under a bell jar by supplying 95% Nitrogen/5%Hydrogen at a rate of 25-30 cfh. • A heating cycle of only 10 seconds was necessary to attain sufficient braze flow which surpasses the required limit of 18 seconds. https://dw-inductionheater.com/brazing-copper-tube-to-brass-fitting-with-induction.html?feed_id=230586&_unique_id=65505e7426754

Brazing Copper Tube with Induction

Brazing Copper Tube with Induction Objective: To braze a copper tube ( 3/8" OD by 2-4" long) into a 3/8" fitting in less than 10 seconds. Heating must take place in a channel type coil to allow for easy loading of parts. Material Copper Tubing and Fitting with Braze and Stay Silv White Flux Temperature 1300°F Frequency 215 kHz Equipment DW-UHF-10kw output solid state induction power supply equipped with a standard heat station containing eight 0.33 μF capacitors for a total of 0.66μF, a step down transformer, and a specifically designed induction heating coil. Process DW-UHF-10kw solid state induction power supply was setup to achieve the following results: · 2.0 kW of power was directly loaded into the copper tube resulting in a heating time of 7.2 seconds to reach the necessary 13000F for brazing. Results& Processing ease was achieved through the design of a unique channel type coil comprised of three turns of 1/8" copper.

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

Induction Brazing Copper Assembly

Induction Brazing Copper Assembly With High Frequency Heating Equipment Objective Brazing a copper pivot assembly Material Two copper uprights 2” (5cm) wide x 4” (10.2cm) high, copper base 3” (7.6cm) x 2” (5cm) and .5” (1.3mm) thick with 2 channels for the uprights to the slide into, braze shims and black flux Temperature 1350 ºF (732 ºC) Frequency 200 kHz Equipment •DW-UHF-20kW induction heating system, equipped with a remote workhead containing two 1.0μF capacitors for a total of 0.5μF • An induction heating coil designed and developed specifically for this application. Process A three turn helical coil is used to heat the base of the assembly. The copper uprights and two braze shims are placed in the grooves in the base and black flux is applied. The assembly is placed in the coil and power is applied for 4 minutes to braze both the uprights in place. Results/Benefits Induction heating provides: • Rapid localized heat which can minimize oxidation and reduce cleaning after joining • Consistent and repeatable joints • Hands-free heating that involves no operator skill for manufacturing • Even distribution of heating https://dw-inductionheater.com/induction-brazing-copper.html?feed_id=229386&_unique_id=6533cde2bc14f

induction brazing stainless steel to copper

Objective Induction Brazing stainless steel to copper tubing. Objective is to evaluate induction brazing solution. Customer is looking to reduce defects and for a cleaner brazing environment. Due to different pipe size and lower volume – evaluation is performed with a induction brazing system.

Test1 Equipment DW-HF-25kw induction brazing machine Materials Copper to Stainless steel tube Power: 12.5kW Temperature: 1400ºF to 1600ºF (760ºC to 871ºC) Time: 9 to 11 seconds

Test2 Equipment DW-HF-25kw induction brazing machine Materials Copper to Stainless steel Power: 12.5kW Temperature: 1400ºF to 1600ºF (760ºC to 871ºC) Time: 9 to 11 seconds

Results and Conclusions: Induction brazing test with U open coil was able to braze the parts in 9 to 11 seconds for the full braze cycle. Operator training with this setup will be minimal.