Induction Brazing Machine

Induction Brazing Machine&Soldering Equipment

Main characteristics:

    1.  IGBT module and inverting technologies of the first generation been used.

    2.  Simple structure and light weight and easy for maintenance.

    3.  Simple to operat ,afew minutes is enough to learn it.

    4.  Simple to install,installation can be done by unprofessional person very easily.

    5.  advantages of the model with timer,the power and the operatingtime of the heating period and the rain period  can be preset repectively,to realize a simple heating curve,this model is suggested to use for batch production to improve the repeatability.

   6.   The separated models are designed to fit the dirty surrounding of some cases.

Specifications：

Series	Model		Input power Max	Input current Max	Oscillate frequency	Input Voltage	Duty cycle
M . F .	DW-MF-15 Induction Generator		15KW	23A	1K-20KHZ According to the application	3*380V 380V±20%	100%
	DW-MF-25 Induction Generator		25KW	36A
	DW-MF-35Induction Generator		35KW	51A
	DW-MF-45 Induction Generator		45KW	68A
	DW-MF-70 Induction Generator		70KW	105A
	DW-MF-90 Induction Generator		90KW	135A
	DW-MF-110 Induction Generator		110KW	170A
	DW-MF-160 Induction Generator		160KW	240A
	DW-MF-45 Induction Heating Rod Forging Furnace		45KW	68A	1K-20KHZ	3*380V 380V±20%	100%
	DW-MF-70 Induction Heating Rod Forging Furnace		70KW	105A
	DW-MF-90 Induction Heating Rod Forging Furnace		90KW	135A
	DW-MF-110 Induction Heating Rod Forging Furnace		110KW	170A
	DW-MF-160 Induction Heating Rod Forging Furnace		160KW	240A
	DW-MF-15   Induction Melting Furnace		15KW	23A	1K-20KHZ	3*380V 380V±20%	100%
	DW-MF-25   Induction Melting Furnace		25KW	36A
	DW-MF-35   Induction Melting Furnace		35KW	51A
	DW-MF-45   Induction Melting Furnace		45KW	68A
	DW-MF-70   Induction Melting Furnace		70KW	105A
	DW-MF-90   Induction Melting Furnace		90KW	135A
	DW-MF-110 Induction Melting Furnace		110KW	170A
	DW-MF-160 Induction Melting Furnace		160KW	240A
	DW-MF-110 Induction Hardening Equipment		110KW	170A	1K-8KHZ	3*380V 380V±20%	100%
	DW-MF-160Induction Hardening Equipment		160KW	240A
H . F .	DW-HF-04 Series	DW-HF-4KW-A	4KVA	15A	100-250KHZ	Single phase 220V	80%
	DW-HF-15 Series	DW-HF-15KW-A DW-HF-15KW-B	15KVA	32A	30-100KHZ	Single phase 220V	80%
	DW-HF-25 Series	DW-HF-25KW-A DW-HF-25KW-B	25KVA	23A	20-80KHZ	3*380V 380V±10%	100%
	DW-HF-35 Series	DW-HF-35KW-B	35KVA	51A
	DW-HF-45 Series	DW-HF-45KW-B	45KVA	68A
	DW-HF-60 Series	DW-HF-60KW-B	60KVA	105A
	DW-HF-80 Series	DW-HF-80KW-B	80KVA	130A
	DW-HF-90 Series	DW-HF-90KW-B	90KVA	160A
	DW-HF-120 Series	DW-HF-120KW-B	120KVA	200A
U . H . F .	DW-UHF-3.2KW		3.2KW	13A	1.1-2.0MHZ	Single phase220V ±10%	100%
	DW-UHF-4.5KW		4.5KW	20A
	DW-UHF-045T		4.5KW	20A
	DW-UHF-045L		4.5KW	20A
	DW-UHF-6.0KW		6.0KW	28A
	DW-UHF-06A		6.0KW	28A
	DW-UHF-6KW-B		6.0KW	28A
	DW-UHF-10KW		10KW	15A	100-500KHZ	3*380V 380V±10%	100%
	DW-UHF-20KW		20KW	30A	50-250KHZ
	DW-UHF-30KW		30KW	45A	50-200KHZ
	DW-UHF-40KW		40KW	60A	50-200KHZ
	DW-UHF-60KW		60KW	90A	50-150KHZ

 

https://dw-inductionheater.com/induction-brazing-machine.html?feed_id=243692&_unique_id=662fe32b8b181

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 Principle-Theory

Induction Brazing Technology

Induction Brazing Principle|Theory Brazing and soldering are processes of joining similar or dissimilar materials using a compatible a filler material. Filler metals include lead, tin, copper, silver, nickel and their alloys. Only the alloy melts and solidifies during these processes to join the work piece base materials. The filler metal is pulled into the joint by capillary action. Soldering processes are conducted below 840°F (450°C) while brazing applications are conducted at temperatures above 840°F (450°C) up to 2100°F (1150°C). The success of these processes depends upon the assembly’s design, clearance between the surfaces to be joined, cleanliness, process control and the correct selection of equipment needed to perform a repeatable process. Cleanliness is ordinarily obtained by introducing a flux which covers and dissolves dirt or oxides displacing them from the braze joint. Many operations are now conducted in a controlled atmosphere with a blanket of inert gas or combination of inert / active gasses to shield the operation and eliminate the need for a flux. These methods have been proven on a wide variety of material and part configurations replacing or complimenting atmosphere furnace technology with a just in time - single piece flow process. Brazing Filler Materials Brazing filler metals can come in a variety of forms, shapes, sizes and alloys depending on their intended use. Ribbon, preformed rings, paste, wire and preformed washers are just a few of the shapes and forms alloys that can be found. The decision to use a particular alloy and/or shape is largely dependent on the parent materials to be joined, placement during processing and the service environment for which the final product is intended. Clearance Affects Strength Clearance between the faying surfaces to be joined determines the amount of braze alloy, capillary action / penetration of the alloy and subsequently the strength of the finished joint. The best fit up condition for conventional silver brazing applications are 0.002 inches (0.050 mm) to 0.005 inches (0.127 mm) total clearance. Aluminum is typically 0.004 inches (0.102 mm) to 0.006 inches (0.153 mm). Larger clearances up to 0.015 inches (0.380 mm) usually lack sufficient capillary action for a successful braze. Brazing with copper (above 1650°F / 900°C) requires the joint tolerance kept to an absolute minimum and in some cases press fit at ambient temperatures to assure minimum joint tolerances while at the brazing temperature. Induction Heating Theory Induction systems provide a convenient and precise way to quickly and efficiently heat a selected area of an assembly. Consideration must be given to the selection of power supply operating frequency, power density (kilowatt applied per square inch), heating time, and induction coil design to provide the required depth of heating in a specific braze joint. Induction heating is non-contact heating by means of transformer theory. The power supply is an AC source to the induction coil that becomes the primary windings of the transformer while the part to be heated is the transformer’s secondary. The work piece heats by the base materials’ inherent electrical resistivity to the induced current flowing in the assembly. Current passing through an electrical conductor (the workpiece) results in heating as current meets resistance to its flow. These losses are low in current flowing through aluminum, copper and their alloys. These non-ferrous materials require additional power to heat than their carbon steel counterpart. The alternating current tends to flow on the surface. The relationship between the frequency of the alternating current and the depth it penetrates the part is known as the reference depth of heating. Part diameter, material type and wall thickness can have an effect on heating efficiency based on the reference depth.   https://dw-inductionheater.com/induction-brazing-principle.html?feed_id=242414&_unique_id=662475e5e0aec

Induction Brazing Aluminum to Aluminum Tube

Induction Brazing Aluminum to Aluminum Tube

Objective Induction brazing of two aluminum pipes

Equipment DW-UHF-6KW-III handheld induction brazing heater Materials Аluminum to aluminum tube Flared at interface 0.25” (6.35mm) Brazed to steel tube 0.19” OD (4.82mm) Power: 6kW Temperature: 1600°F (871°C) Time: 3sec

Results and Conclusions: Induction heating provides:

• Strong durable joints
• Selective and precise heat zone, resulting in less part distortion and joint stress than welding
• 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-aluminum-to-aluminum-tube.html?feed_id=241435&_unique_id=661b2d66909c9

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 Carbide Onto Steel Part

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:

1. 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.
2. The custom made coil was then placed over the steel piece, where is was set for 14 seconds to heat the alloy.
3. The alloy was heated at approximately 1500°F (815)°C
4.  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

https://dw-inductionheater.com/induction-brazing-carbide-onto-steel-part.html?feed_id=241299&_unique_id=6619bfbf80a7e

High frequency induction brazing steel tube to steel fitting

Objective Handheld high frequency induction brazing of a steel tube to a steel fitting Recommended Equipment The recommended equipment for this application is the DW-UHF-6KW-III handheld induction brazing heater heat station.

Materials: Steel tube to steel fitting braze using Lucas-Milhaupt Easy FLO 3 brazing alloy rings and Harris Black Brazing Flux. Power: 3.5kW to 6.6kW Temperature: 1300°F to 1400°F (704°C to 760°C ) Time: 6 to 8 Seconds  

  https://dw-inductionheater.com/high-frequency-induction-brazing-steel-tube-to-steel-fitting.html?feed_id=240961&_unique_id=6616e47156a1e

Induction Brazing Copper T Pipe With Induction Heating Machine

Objective Evaluate replacing of flame copper t pipe brazing with induction brazing. Equipment DW-HF-25kw high frequency induction heating machine

Materials

• Copper main tube – 1.13” (28.7 0mm) OD 1.01” (25.65 mm) ID • Riser tube copper – 0.84” (21.33 0mm)  OD,  0.76” (19.30 0mm)  ID Power: Power manually reduced from max output of 10kW to 15kW to provide even heat distribution on the assembly with the modified test coil. NOTE: Heat time can be improved with custom coil design. Temperature:  Approximately 704° C (1300° F) Time: 25sec

Process Steps: The copper tubes were cleaned and assembled. Two preformed alloy rings were made from available alloy in lab for the demonstration.  The wire used measured 0.787mm (0.031”) in diameter  Both the riser an base copper tubes were pre-fluxed with white braze flux. The assembly was placed in the test coil per the video bellow and the alloy flowed to form a joint at the “T” interface in 30seconds. Results and Conclusions: The target heat time for the smallest T joint assembly is 20 seconds . Using a lab test coil, we were able to effect a braze in the interface section of the tubes (copper) in 30 seconds.  

 

https://dw-inductionheater.com/induction-brazing-copper-t-pipe-with-induction-heating-machine.html?feed_id=240796&_unique_id=661576c3c085d

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 automotive copper heating exchanger pipes

High frequency induction brazing automotive copper heating exchanger pipes

A manufacturer of appliances wants to achieve automation in their induction brazing process. Their goal is to be able to induction brazing automotive copper heating exchanger pipes. We carried out several tests to choose the best induction heating products which can fit their needs. The HLQ automated induction brazing system can be used for their specific process DW-UHF-20KW induction brazing machine The DW-UHF-20KW comes equipped with a  20kw induction heating system.This powerful induction heating solution can be successfully integrated into a production line. Equipment:  DW-UHF-20KW induction brazing machine Time: 12 sec. Materials: Copper pipes

Process: The robotic arm moves with great precision and allows complete control over the process. The alloy rings melt and perfectly braze all joints. One joint is being brazed for 12 seconds.

https://dw-inductionheater.com/induction-brazing-automotive-copper-heating-exchanger-pipes.html?feed_id=238561&_unique_id=6602e636de6f3

Induction Brazing Stainless Steel Tubing Joints

The Professional Induction Brazing Stainless Steel Tubing Joints Technology

The goal of this induction brazing application test is for Induction Brazing Stainless Steel Tubing Joints evenly for increased repeatability. Industry: Automotive Equipment:  DW-UHF-10KW induction brazing machine Time: 15 sec. Materials: Stay Silv Black Flux Temperature:  1472°F  (800°C) Power: 8 kW

Process: The two stainless tubes where joined together and an alloy ring was placed around the joint. Black flux was then applied to the joint for a better induction brazing process. The work piece was placed inside the helical coil for 15 seconds where 8 kW of induction heating power was applied. The work piece reached 1472°F  (800°C) and was successfully brazed.  The HLQ induction heating equipment recommend for this application is the  DW-UHF-10KW induction brazing heater along with a 10 kW power supply.

https://dw-inductionheater.com/high-frequency-induction-brazing-stainless-steel-tubing-joints.html?feed_id=238493&_unique_id=66022ee650bb7