Induction Brazing Copper Tube of Heat Exchanger

Induction Brazing Copper Tube of Heat Exchanger https://dw-inductionheater.com/induction-brazing-copper-tube-of-heat-exchanger.html?feed_id=270822&_unique_id=67be28da7d6f7

Induction Brazing Copper T Pipe With Induction Heating Machine

Induction Brazing Copper T Pipe With Induction Heating Machine https://dw-inductionheater.com/induction-brazing-copper-t-pipe-with-induction-heating-machine.html?feed_id=270300&_unique_id=67b73cd74f87b

Induction Brazing T Shaped Copper Tubing Assemblies

Induction Brazing T Shaped Copper Tubing Assemblies https://dw-inductionheater.com/induction-brazing-t-shaped-copper-tubing-assemblies.html?feed_id=268183&_unique_id=679b8d6029a4c

Induction Brazing Brass Studs to Copper Pipes

Induction Brazing Brass Studs to Copper Pipes https://dw-inductionheater.com/induction-brazing-brass-studs-to-copper-pipes.html?feed_id=267748&_unique_id=67959eabde320

Induction Brazing copper wire to copper cylinder

Induction Brazing copper wire to copper cylinder https://dw-inductionheater.com/induction-brazing-copper-wire-to-copper-cylinder.html?feed_id=267603&_unique_id=6793a48a03fb9

Induction Brazing Copper To Copper Parts

Induction Brazing Copper To Copper Parts https://dw-inductionheater.com/induction-brazing-copper-to-copper-parts.html?feed_id=267371&_unique_id=6790ad14138c7

Induction Brazing Copper Tube

Induction Brazing Copper Tube https://dw-inductionheater.com/product/induction-brazing-copper-tube?feed_id=261948&_unique_id=6746dff1a34f0

Induction Brazing Copper

Induction Brazing Copper https://dw-inductionheater.com/product/induction-brazing-copper?feed_id=261861&_unique_id=67458e6796add

Induction Brazing Copper Pipe Fittings

Induction Brazing Copper Fittings Objective: Copper 'tees' and 'ells' are to be brazed to the aluminum body of a refrigeration valve Material: customer's valve copper fittings braze Temperature: 2550 ºF (1400°C) Frequency: 585 kHz Equipment: DW-UHF-10kw induction heating system including a workhead containing two 1.5μF capacitors (total 0.75μF) and a three-turn helical coil Process: The valve is placed inside the coil and RF induction heating power is applied until the part is heated to the required temperature and the braze is seen to flow into the joint. Two tube sizes were run using the same induction heating system settings with differing cycle times. Results/Benefits • energy is applied only to the zone to be heated • heating of the joint/braze is uniform and repeatable https://dw-inductionheater.com/induction-brazing-copper-pipe-fittings.html?feed_id=253405&_unique_id=668e2619682c9

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=252766&_unique_id=66886faf6bfe7

Brazing Brass To Copper With Induction

Brazing Brass To Copper With Induction Objective: To braze brass end-connectors to copper tubes used in aircraft assembly air lines Material brass end connectors, copper tubes of different diameters Temperature 1400 ºF 750°C Frequency 350 kHz Equipment DW-UHF-4.5KW induction heating system, including a three turn helical induction coil using two 0.33μF capacitors (total 0.66μF) Process For smaller diameter parts, flux is applied to the entire part and the copper tube to brass joint is assembled using brazing preforms (allowing for the same amount of braze in each joint). The assembly is placed in the coil and heated for 20-30 seconds reaching a temperature of 1400°F. For larger copper tube assemblies, the same process is used, but the braze alloy is stick-fed to the joint to prevent the alloy from flowing out of the joint. A foot switch control is recommended to enable better control of the process. Results/Benefits Economy: Power is consumed during the heating only Consistency: the results of braze joints are repeatable and uniform https://dw-inductionheater.com/brazing-brass-to-copper-with-induction.html?feed_id=251408&_unique_id=667ade3ae905e

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=250876&_unique_id=6676957123c3e

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=249677&_unique_id=666a7153614d4

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

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Induction Brazing copper wire to copper cylinder

Objective

Induction Brazing copper wire to coppre cylinder with Handheld induction brazing heater

Equipment

20kw handheld induction brazing heater

Materials

Copper wire to Copper cylinder

Power: 12 kW

Temperature: 1600°F ( 871°C )

Time: 5 sec

Results and Conclusions:

• Induction Brazing successfully in 5 seconds


• Precise control of the time and temperature


• Power on demand with rapid heat cycles


• Reduction in defects due to overheating

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Induction Brazing Brass Studs to Copper Pipes

Induction Brazing Brass Studs to Copper Pipes

Objective:

Induction brazing brass studs to copper pipes

The Client:

A manufacturer of coils for industrial heating applications.

Equipment:

DW-UHF-40KW Induction Brazing Systems – two modules.

Materials: Brass stud ( size:  25mm diameter, 20 mm height )

Power: 30 kW

The Process: 

The main challenge during this induction brazing process is to ensure that the design of the coil is one that eases the technician to position it in the most convenient way. The induction coil should allow for the second stud to be pre-heated without melting the first one.

First, the electrolytic copper section is wound on a steel former by a gas torch while an equal spacing between the turns is maintained. Then, the copper turn is heated close to the required temperature and while the power is ON, the technician should make sure to manually position the brass stud with the brazing ring at the designated centre. During the process of brazing, the induction coil is moving at a speed of 58 mm per minute – 33 kW.

If the power is increased, the speed changes accordingly.

Results and Conclusions:

• A fast, clean and safe induction brazing process


• Guaranteed repeatability


• Precise control of time and temperature

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Induction Brazing T Shaped Copper Tubing Assemblies

High Frequency Induction Brazing T Shaped Copper Tubing Assemblies

Objective:

Test 1 – Induction brazing T-shaped copper tubing assemblies – 3 joints simultaneously

Test 2 – Induction brazing copper tubing

Industry: HVAC

Materials: Copper tubers  6, 8, 10, 12 mm ( 0¹⁵⁄_64, 0⁵⁄_16, 0²⁵_⁄64, 0¹⁵_⁄32inch. ); thickness: 1 mm ( 0³⁄₆₄ inch.)

Alloy: Cu-P-Ag rings

TIP: The use of alloy rings is highly recommended with a hand-held brazing gun.

Equipment: DW-UHF-20kw induction brazing machine

Power:

Test 1 ( 7-8kW )

Test 2 ( 6.5-9.2kW )

Time: 8 secs.

Coil: Regular induction heating coil. Custom coil design is possible upon request.

The Process:

We successfully carried out two induction brazing tests with several copper assemblies.  First, Cu-P-Ag alloy rings were placed around the thinner of the copper tubings. No additional flux was needed.  The pipes were then carefully aligned. The process of induction brazing was initiated. Once the induction brazing was complete, the two samples were submerged in cold water in order to be cooled instantly. The excessive amount of flux can be furtherly cleaned.

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