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 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 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.

https://dw-inductionheater.com/induction-brazing-t-shaped-copper-tubing-assemblies.html?feed_id=238359&_unique_id=6601784ba36e6

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

https://dw-inductionheater.com/induction-brazing-copper-wire-to-copper-cylinder.html?feed_id=237720&_unique_id=65fbc1d601228

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 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=230886&_unique_id=655782768f6d8

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=230646&_unique_id=6551cbf8aabdc

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=230076&_unique_id=65443a9c69e74

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.

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=229896&_unique_id=653ff1a5c894a

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.  

 

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=229386&_unique_id=6533cde2bc14f

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

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

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=224311&_unique_id=64e3cde37264d