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 brass pipe to brass part

Objective High Frequency Induction Brazing brass pipe to brass part and a brass tip in under one minute using induction.

Equipment DW-UHF-6KW-III handheld induction brazing machine 2 turns coil Materials • Wide brass part • Brass pipe • Silver-based brazing alloy, provided by customer

Test 1 – Pipe to wide part: Key Parameters Power: 4.4 kW Temperature: Approximately 1400° F (760° C) Time: 38 sec

Test 2 – Pipe to tip: Key Parameters Power: 4.4 kW Temperature: Approximately 1400° F (760° C) Time: 17 sec

Process: Test 1

• The wide part and brass pipe are assembled and a brazing alloy ring is placed between them.
• The assembly is put inside the induction heating coil and induction heat is applied.
• The joint is completed in 38 seconds.

Test 2

• The tip and pipe are assembled and a brazing alloy ring is placed between them.
• The assembly is put inside the coil and induction heat is applied.
• The joint is completed in 17 seconds.

Results/Benefits: Induction 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 process than flame brazing

https://dw-inductionheater.com/induction-brazing-brass-pipe-to-brass-part.html?feed_id=236860&_unique_id=65f555b095631

Brazing Brass Fittings With Induction

Brazing Brass Fittings With Induction Objective :To heat brass tubing assemblies to 750°C for a brazing application. The tubing diameter varies from 3 to 8 inches (76.2 to 203.2 mm) Material: Brass tubing Brass flange Braze rings Braze flux Temperature :1382°F (750°C) Frequency 200 kHz Equipment DW-UHF-20KW, 150-500 kHz induction heating power supply, equipped with a remote heat station containing eight 1.0 μF capacitors (total 2.0 μF). A multi-turn helical coil induction heating coil designed and developed specifically for this application. Process The parts are disassembled. All connections are cleaned and braze flux is applied to the entire surface of the assembly. Before assembling the parts an induction coil is slipped over the tube. The brass coupling is placed over the brass tubes. The flux on the parts is allowed to dry before heating. The induction heating power is applied until the braze flows well at the joint. The assembly heats well to 1382°F (750°C) and melts the braze alloy all around the tube. Heating time is several minutes depending on flange diameter. Results/Benefits The coil allows heating at the best possible efficiency which reduces the cycle time and the conducted heat along the brass tubes. https://dw-inductionheater.com/brazing-brass-fittings-with-induction.html?feed_id=230496&_unique_id=654e39f56072c

Brazing Brass to Aluminum with Induction

Brazing Brass to Aluminum with Induction 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 360 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 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 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/brazing-brass-to-aluminum-with-induction.html?feed_id=230136&_unique_id=6545a82c927a5

Induction Brazing Brass Faucet

Induction Brazing Brass Faucet Objective Brazing two joints on a brass bathroom faucet assembly Material Brass bathroom fittings 1” OD, brazing rings, flux Temperature 1148 ºF (620 ºC) Frequency 90 kHz Equipment • DW-UHF-30 kW induction heating system, equipped with a remote workhead containing eight 1.0 μF capacitors for a total of 8.0 μF • An induction heating coil designed and developed specifically for this application. Process A two turn C shaped coil is used to braze the faucet assembly. The braze rings are placed at the joint, the parts assembled and fluxed. The first braze joint is heated for 30 seconds and the braze ring flows. The assembly is rotated & the second joint is heated for 30 seconds to flow the braze ring. The two brazes are completed in 60 seconds. Results/Benefits Induction heating provides: • Faster, repeatable and consistent results • Localized heat produces neat and clean joints • Hands-free heating that involves no operator skill for manufacturing • Even distribution of heating https://dw-inductionheater.com/induction-brazing-brass.html?feed_id=229416&_unique_id=653484c35006d

Brazing Brass to Aluminum with Induction

Brazing Brass to Aluminum with Induction 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 360 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 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 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

Brazing Brass to Aluminum with Induction

Brazing Brass to Aluminum with Induction 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 360 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 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 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

Induction Brazing Brass Faucet

Induction Brazing Brass Faucet Objective Brazing two joints on a brass bathroom faucet assembly Material Brass bathroom fittings 1” OD, brazing rings, flux Temperature 1148 ºF (620 ºC) Frequency 90 kHz Equipment • DW-UHF-30 kW induction heating system, equipped with a remote workhead containing eight 1.0 μF capacitors for a total of 8.0 μF • An induction heating coil designed and developed specifically for this application. Process A two turn C shaped coil is used to braze the faucet assembly. The braze rings are placed at the joint, the parts assembled and fluxed. The first braze joint is heated for 30 seconds and the braze ring flows. The assembly is rotated & the second joint is heated for 30 seconds to flow the braze ring. The two brazes are completed in 60 seconds. Results/Benefits Induction heating provides: • Faster, repeatable and consistent results • Localized heat produces neat and clean joints • Hands-free heating that involves no operator skill for manufacturing • Even distribution of heating

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"]

induction brazing brass pipe to brass part

Objective High Frequency Induction Brazing brass pipe to brass part and a brass tip in under one minute using induction.

Equipment DW-UHF-6KW-III handheld induction brazing machine 2 turns coil Materials • Wide brass part • Brass pipe • Silver-based brazing alloy, provided by customer

Test 1 – Pipe to wide part: Key Parameters Power: 4.4 kW Temperature: Approximately 1400° F (760° C) Time: 38 sec

Test 2 – Pipe to tip: Key Parameters Power: 4.4 kW Temperature: Approximately 1400° F (760° C) Time: 17 sec

Process: Test 1

• The wide part and brass pipe are assembled and a brazing alloy ring is placed between them.
• The assembly is put inside the induction heating coil and induction heat is applied.
• The joint is completed in 38 seconds.

Test 2

• The tip and pipe are assembled and a brazing alloy ring is placed between them.
• The assembly is put inside the coil and induction heat is applied.
• The joint is completed in 17 seconds.

Results/Benefits: Induction 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 process than flame brazing

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=223411&_unique_id=64dca846dfa63

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

https://dw-inductionheater.com/induction-brazing-brass-studs-to-copper-pipes.html?feed_id=221086&_unique_id=64c5bde9f35f8

induction brazing brass pipe to brass part

Objective High Frequency Induction Brazing brass pipe to brass part and a brass tip in under one minute using induction.

Equipment DW-UHF-6KW-III handheld induction brazing machine 2 turns coil Materials • Wide brass part • Brass pipe • Silver-based brazing alloy, provided by customer

Test 1 – Pipe to wide part: Key Parameters Power: 4.4 kW Temperature: Approximately 1400° F (760° C) Time: 38 sec

Test 2 – Pipe to tip: Key Parameters Power: 4.4 kW Temperature: Approximately 1400° F (760° C) Time: 17 sec

Process: Test 1

• The wide part and brass pipe are assembled and a brazing alloy ring is placed between them.
• The assembly is put inside the induction heating coil and induction heat is applied.
• The joint is completed in 38 seconds.

Test 2

• The tip and pipe are assembled and a brazing alloy ring is placed between them.
• The assembly is put inside the coil and induction heat is applied.
• The joint is completed in 17 seconds.

Results/Benefits: Induction 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 process than flame brazing

https://dw-inductionheater.com/induction-brazing-brass-pipe-to-brass-part.html?feed_id=220186&_unique_id=64bde142a19f8

Brazing Brass Fittings With Induction

Brazing Brass Fittings With Induction Objective :To heat brass tubing assemblies to 750°C for a brazing application. The tubing diameter varies from 3 to 8 inches (76.2 to 203.2 mm) Material: Brass tubing Brass flange Braze rings Braze flux Temperature :1382°F (750°C) Frequency 200 kHz Equipment DW-UHF-20KW, 150-500 kHz induction heating power supply, equipped with a remote heat station containing eight 1.0 μF capacitors (total 2.0 μF). A multi-turn helical coil induction heating coil designed and developed specifically for this application. Process The parts are disassembled. All connections are cleaned and braze flux is applied to the entire surface of the assembly. Before assembling the parts an induction coil is slipped over the tube. The brass coupling is placed over the brass tubes. The flux on the parts is allowed to dry before heating. The induction heating power is applied until the braze flows well at the joint. The assembly heats well to 1382°F (750°C) and melts the braze alloy all around the tube. Heating time is several minutes depending on flange diameter. Results/Benefits The coil allows heating at the best possible efficiency which reduces the cycle time and the conducted heat along the brass tubes.

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"]

Induction Brazing Brass Faucet

Induction Brazing Brass Faucet Objective Brazing two joints on a brass bathroom faucet assembly Material Brass bathroom fittings 1” OD, brazing rings, flux Temperature 1148 ºF (620 ºC) Frequency 90 kHz Equipment • DW-UHF-30 kW induction heating system, equipped with a remote workhead containing eight 1.0 μF capacitors for a total of 8.0 μF • An induction heating coil designed and developed specifically for this application. Process A two turn C shaped coil is used to braze the faucet assembly. The braze rings are placed at the joint, the parts assembled and fluxed. The first braze joint is heated for 30 seconds and the braze ring flows. The assembly is rotated & the second joint is heated for 30 seconds to flow the braze ring. The two brazes are completed in 60 seconds. Results/Benefits Induction heating provides: • Faster, repeatable and consistent results • Localized heat produces neat and clean joints • Hands-free heating that involves no operator skill for manufacturing • Even distribution of heating

Brazing Brass to Aluminum with Induction

Brazing Brass to Aluminum with Induction 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 360 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 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 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

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"]