Induction Brazing Carbide Onto Steel Part

Objective Brazing carbide onto steel workpiece Equipment DW-UHF-6KW-III Handheld Induction Brazing Heater Key Parameters Power: 4kW Temperature: Approximately 1500°F (815°C) Time: 16 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:

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.
The custom made coil was then placed over the steel piece, where is was set for 14 seconds to heat the alloy.
The alloy was heated at approximately 1500°F (815)°C
The whole piece is left alone and cooled with ambient air

Results/Benefits:

Brazing was successful all in under 20 seconds with 3kW
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

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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 Carbide Onto Steel Part

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induction brazing copper and brass rods

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