Induction Soldering Copper Cables to Copper Pins
Objective:
The objective of this
induction heating application is to solder cables to copper pins for harness manufacturing. The customer is a manufacturer of mission-critical test systems for the Aerospace Industry. The goal is to reduce soldering time from 10 minutes by hand to less than 1 minute with the help of an
induction heating system and increase solder quality and repeatability.
Equipment:
HLQ has a line of induction soldering equipment, typically used in a similar application – DW-UHF series,
high frequency induction heating systems for induction soldering and brazing of small components and parts.
Process:
The customer provided a large cable with 0.2”(5.08 cm) OD and a pin 1”(2.5 cm) long, 0.178” (0.44 cm) OD, a cable receiver 0.2” (5.08 cm) long, 0.169” (0.42 cm) ID, 0.19” OD and a small cable with 0.09” (0.22 cm) OD, as well as, a small pin 0.114”( 0.28 cm) OD and a cable receiver 0.16”( 0.40 cm) long, 0.07”( 0.17 cm) ID. 0.129” (0.32 cm) OD.
Induction Soldering paste was applied inside the cable receiver on the pin and to the stripped end of the cable. The pin was then placed in its holder. The induction heating coil entirely covered the cable receiver. Induction soldering with the DW-UHF-6KW-I handheld induction brazing system was completed in 2 seconds at 60% power to a temperature of ~600°F (315°C).
Industry: Aerospace & Defense
Soldering Steel To Brass With Induction IGBT Soldering Heater
Objective Heat an assembly of small, gold-plated steel connectors to a brass block.
Material Approx. 1/8” (3.2mm) diameter gold-plated steel connectors, 1”(25.4mm) square x 1/4” thick brass block
Temperature 600°F(315.6ºC)
Frequency 240 kHz
Equipment • DW-UHF-6kW induction heating system equipped with a remote workhead.
• An induction heating coil designed and developed specifically for this application.
Process A two-turn helical coil is used to provide uniform heat to parts assembly. Solder paste and flux are applied to the joint area and power is applied for 20 seconds to solder the parts. Proper
fixturing is needed to hold the parts in position.
Results/Benefits Induction heating provides:
• Rapid, localized heating to specific regions of part
• Neat and clean joints
• Flameless processing
Induction Soldering Copper Tube With High Frequency Heating Units
Objective: To heat a section of 3/8" copper tubing along with a 900 elbow for soldering. The copper tubing is to be used in Ice Machine Evaporator Assemblies, and soldering takes place after the tubes have been placed within the assembly. Heating must take place in a channel type coil to provide easy access, once the tubing has been installed. Solder can be manually fed after temperature
has been reached.
Material: 3/8" Thin Walled Copper Tubing and 900 Elbow
Temperature: 6000F
Application: Through the use of the DW-UHF-20kW output solid state induction power supply and a unique three (3) turn channel coil, the following results were achieved:
6000F was reached in 10 seconds.
A quality solder joint was observed with adequate flow and surface texture.
Equipment: DW-UHF-20kW output solid state induction power supply including one (1) remote heat station containing one (1) 1.2 μF capacitor, and a unique three (3) turn channel coil.
Frequency: 200 kHz
Induction Soldering Copper Tap on a Speaker Ring with IGBT Induction Heater
Objective Heat copper tab until the solder reflows.
Material Copper tab 0.25 X 0.25 inch square about 0.05 inches thick. Lead free solder material (higher melting temperature than regular solder.)
Temperature 500 ºF for 1.25 seconds
Frequency 286 kHz
Equipment DW-UHF-4.5 kW, 150-400 kHz solid state induction heating system equipped with a remote heat station containing one 1.2 μF capacitor and a specially-designed work coil..
A multi-turn helical coil about 3/16 inch internal diameter made out of 1/16 inch diameter tubing.
Process Solder wire is fed onto speaker tab area using an automatic wire feeder. It is then heated to re-flow the solder.
Results/Benefits With an efficient coil design induction heating easily reaches the desired reflow temperature in a very short amount of time.
Induction Soldering Copper Wires With IGBT High Frequency Heating Units
Objective Soldering two copper wires to pre-installed turrets on a copper buss bar
Material Solder dipped copper/nickel buss bar, 2 tinned stranded copper wires, brazing stick
Temperature 446 ºF (230 ºC)
Frequency 230 kHz
Equipment • DW-UHF-6kW induction heating system, equipped with a remote workhead containing one 1.2μF capacitor.
• An induction heating coil designed and developed specifically for this application.
Process A four turn split helical coil is used to solder the buss bar assembly. The 2 copper wires are applied to the turrets and power is applied for 30 seconds. The brazing stick is fed by hand to the heated parts and the braze flows evenly, creating the joint.
Results/Benefits Induction heating provides:
• Reduced solder time
• Even distribution of heating
• Joint to joint consistency
