Brazing copper tube to brass fitting

High frequency Induction brazing copper tube to brass fitting process

Objective Induction brazing copper to brass fitting using brazing alloy and flux within 60 seconds.

Equipment 1.DW-UHF-6KW-III handheld induction heater 2 turn helical coil Materials • Brass fitting • Copper tubing • Silver brazing alloy (pre-formed) • Flux Key Parameters Temperature: Approximately 1350 °F (732°C)

Process:

1. For Induction Brazing Copper to Brass, first the copper tubing and brass fitting were assembled together.
2. A pre-form of the silver brazing alloy was seated above the joint, and flux was added.
3. The assembly was placed the two-turn helical coil, and positioned so the targeted joint was centered in the coil.
4. After 60 seconds in the coil, the brazing was complete.
5. The material was cooled in water following the completion of brazing.
6. The joint was then cross-sectioned to validate that the induction brazing process had produced a strong, high quality joint.

Results/Benefits: Induction brazing heating provides:

• 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

https://dw-inductionheater.com/brazing-copper-tube-to-brass-fitting.html?feed_id=243162&_unique_id=662c50aa0c3fa

Induction Brazing Copper Tube of Heat Exchanger

Induction Brazing Copper Tube of Heat Exchanger

Objective Brazing heat exchanger copper to copper pipes Industry Various industries Base material Copper tubes – 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-6KW-III handheld induction brazing heater Key Parameters Power: 6KW Time: ≈ 10s

Process A manufacturer of heat exchangers for various industries wanted to increase operator safety and production rate during the process of 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 brazing of two joints to be performed simultaneously. HLQ team recommended using the UBraze 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 10 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 heating

https://dw-inductionheater.com/induction-brazing-copper-tube-of-heat-exchanger.html?feed_id=241367&_unique_id=661a7699e7b00

Induction Brazing Copper Tube For Refrigeration

Objective Induction Brazing of a Copper Refrigeration Tube to Steel Tube

Equipment DW-UHF-6KW-I Handheld Induction Brazing System Materials Copper Refrigeration  to steel tube Copper tube – 0.2” (5.08mm) at the interface Steel tube Flared interface 0.25” (6.35mm) Power: 6kW Temperature: 1600°F (871°C) Time: 6 sec

Results and Conclusions:

• Successfully braze copper to steel tube in 6 seconds
• Strong durable joints
• Precise control of the time and temperature
• Reduction in defects due to overheating
• Technology without pollution, clean and safe

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https://dw-inductionheater.com/induction-brazing-copper-tube-for-refrigeration.html?feed_id=240864&_unique_id=66162da90acc5

Induction Handheld Brazing Copper To Steel Tube

Objective Braze copper cylinders, copper wires, and steel tubes in under 20 seconds using the DW-UHF-6KW-III handheld induction heating system. Equipment DW-UHF-6KW-III handheld induction heating system Test 1 Materials • Copper cylinder to copper wire. Power: 6.6kW Temperature: 871° C (1600° F) Time: 20 sec Test 2 Materials • Copper cylinder to steel tube. Power: 10 kW Temperature: 871° C (1600° F) Time: 10 to 11 sec Results and Conclusions: It is recommended to use brazing alloy preforms / rings instead of a brazing rod. This allows the user to use both hands to hold the U-Braze. It also improves the quality of the braze and repeatability by distributing the correct amount of alloy all around the braze joint every time. When brazing copper to steel, it is best to preheat the copper to avoid overheating the steel piece since the copper is harder to heat.   [wpforms id="3947"] https://dw-inductionheater.com/induction-handheld-brazing-copper-to-steel-tube.html?feed_id=240602&_unique_id=661409426faca

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

   

[wpforms id="3947"] https://dw-inductionheater.com/induction-brazing-copper-and-brass-rods.html?feed_id=240534&_unique_id=6613527647eb1

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 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=238126&_unique_id=65ff5460eaa7b

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 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

https://dw-inductionheater.com/induction-brazing-copper-rods-to-brass-strips.html?feed_id=236928&_unique_id=65f60b623c1e1

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