Induction Brazing Carbide To Stainless Steel

Induction Brazing Carbide To Stainless Steel Shaft With IGBT Heating Units Objective Brazing a cone shaped carbide to a stainless steel shaft for a digger Material Cone shaped carbide 1.12” (28.4mm) dia, 1.5”(38.1mm) tall, stainless steel shaft 1.12” (28.4mm) dia and various length, black brazing flux and braze shims Temperature 1500 ºF (815 ºC) Frequency 277 kHz Equipment • DW-UHF-10 kW 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 braze the carbide to the shaft. The steel shaft is fluxed and the braze shim placed on top. The carbide tip is fluxed and placed on top of the shim, lining up the countersunk hole in the carbide. The hole is not fluxed because the flux outgases and causes the carbide to build up pressure and attempt to repel from the shaft. Power is applied for 85 seconds for the braze shim to flow and make a good joint. DAWEI’s customer has a customer who is unhappy with the braze quality of their digger so our customer is looking for a better quality brazing process. DAWEI’s customer is very happy with the sample brazed diggers and the help he received from the Ameritherm lab in developing his brazing process. Results/Benefits Induction heating provides: • Rapid localized heating only where needed • Creates clean, controllable joints • Hands-free heating that involves no operator skill for manufacturing • Even distribution of heating                           https://dw-inductionheater.com/induction-brazing-carbide-to-stainless-steel.html?feed_id=244304&_unique_id=6636501477c8b

Brazing stainless steel with induction

High frequency induction brazing stainless steel tube to stainless steel fitting with DW-HF-25kw-A induction heater.

Objective Brazing stainless steel tubing and stainless steel fittings Equipment DW-HF-25kw-A induction brazing machine

Materials 1.75″(44.45mm) Hexagon fitting Power: 10.52 kW Temperature: 1300°F (704°C) Time: 30 seconds

Results and Conclusions:

• Induction heating pinpoints the heat to the desired area of the part
• Improved process control for precise heating to a desired temperature
• Power on demand and rapid, consistent heat cycles
• Technology without pollution, which is both clean and safe

https://dw-inductionheater.com/brazing-stainless-steel-with-induction.html?feed_id=243094&_unique_id=662b99f85f682

Handheld Brazing Stainless Steel Tube

Handheld Brazing Stainless Steel Tube With Handheld Induction Heater

Objective Induction Braze stainless steel tubes to copper tubes with handheld induction brazing heater. 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 handheld induction heating system.

Equipment DW-UHF-6KW-III handheld induction brazing heater   Materials Copper to Stainless steel tube Power: 6.6kW Temperature: 1400ºF to 1600ºF (760ºC to 871ºC) Time: 9 to 11 seconds

Results and Conclusions: Induction brazing test with Handheld Induction Brazing Heater was able to braze the parts in 9 to 11 seconds for the full braze cycle.

https://dw-inductionheater.com/handheld-brazing-stainless-steel-tube.html?feed_id=241095&_unique_id=66179b4ff3f58

High Frequency Brazing Stainless Steel Fittings

Objective High Frequency Brazing stainless steel fittings to corogated (SS) hoses. The hoses are with sizes ID 1.575in (40mm) and ID 2.99in (76 mm).  The customer has never used induction heating before and is not familiar with the induction process. The goal of this test is to prove the strength of the joints. Equipment DW-UHF-10KW induction brazing machine Materials • Flexible metal hose • Ag45Sn brazing alloy

Test 1 Key Parameters Flexible metal hose with ID 1.575in (40mm) Equipment: DW-UHF-10KW induction brazing heater, custom coil – ID 1.654in (42mm), 1 turn Temperature: approximately 1382°F (750°C) Power: Pre-curie – 7kW Time: 28seconds

Test 2 Key Parameters Flexible metal hose with ID 2.913in (74mm) Equipment: DW-UHF-10kw induction brazing heater, custom coil – ID 2.992in (76mm), 1 turn Temperature: approximately 1382°F (750°C) Power: Pre-curie – 8 kW Time: 1 minute 20 seconds

Process:

1. Hose and fittings are prepared with borax flux paste in the surface area.
2. Brazing rod is prepared in form of a ring fitting around the diameter of the joint.
3. The hose and the fittings are placed into the coil.
4. Induction heating is applied to the area until the braze is completed.

Results/Benefits:

1. Power supply DW-UHF-10KW induction brazing machine meets the requirements for this process.
2. For better performance for bigger diameter joints, we recommend power supply DW-UHF-10KW  induction brazing heater.A special custom coil can be designed as well.
3. For the tests, static induction was used (see video), but flexible leads and coil or our DW-UHF series are also recommended.

Induction heating provides:

• Strong durable joints
• Selective and precise heat zone, resulting in less part distortion and joint stress
• 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/high-frequency-brazing-stainless-steel-fittings-machine.html?feed_id=240466&_unique_id=66129ba5d669a

induction brazing stainless steel to steel

High frequency magnetic induction brazing stainless steel to steel process

HLQ team was provided with 2 different parts to be brazed in our test laboratory. Objective: Induction Brazing of a 0.15’’/ 3.81mm stainless steel pin to a steel base. Equipment:  DW-UHF-6KW-III handheld induction brazing system  Industry: Appliances & HVAC Materials: Steel hexagon (base 1’’/ 25.4 mm diameter; 0.1’’/ 2.54 mm wall thickness) A stainless steel pin (0.15’’/ 3.81 mm) Other Materials:  All-purpose black brazing flux Power: 1.43 kW Temperature: 1400 °F/ 760°C Time: 8 seconds Process: The two workpieces were carefully positioned together. All-purpose induction brazing black flux was added because it is ideal for high-temperature applications where rapid, localized heating is needed. The process of induction brazing was performed successfully within 8 seconds by using the  DW-UHF-6KW-III handheld induction brazing system, producing the induction heating power of 1.43 kW at 1400 °F/ 760°C. https://dw-inductionheater.com/high-frequency-magnetic-induction-brazing-stainless-steel-to-steel-process.html?feed_id=238194&_unique_id=66000a7b141d8

induction brazing stainless steel tubing process

Induction Brazing stainless steel tubing and stainless steel fittings Technology

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

Materials 1.75″ (44.45mm) Hexagon fitting Power: 10.52 kW Temperature: 1300°F (704°C) Time: 30 seconds

Results and Conclusions:

• Induction heating pinpoints the heat to the desired area of the part
• Improved process control for precise heating to a desired temperature
• Power on demand and rapid, consistent heat cycles
• Technology without pollution, which is both clean and safe

https://dw-inductionheater.com/induction-brazing-stainless-steel-tubing-process.html?feed_id=237788&_unique_id=65fc787e82368

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 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

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

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

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.

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.

Brazing stainless steel with induction

High frequency induction brazing stainless steel tube to stainless steel fitting with DW-HF-25kw-A induction heater.

Objective Brazing stainless steel tubing and stainless steel fittings Equipment DW-HF-25kw-A induction brazing machine

Materials 1.75″(44.45mm) Hexagon fitting Power: 10.52 kW Temperature: 1300°F (704°C) Time: 30 seconds

Results and Conclusions:

• Induction heating pinpoints the heat to the desired area of the part
• Improved process control for precise heating to a desired temperature
• Power on demand and rapid, consistent heat cycles
• Technology without pollution, which is both clean and safe

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.