Induction Soldering Copper Tap

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. https://dw-inductionheater.com/induction-soldering-copper-tap.html?feed_id=246140&_unique_id=664997f496486

Induction Soldering Brass Corner Joint

Hig Frequency Induction Soldering Brass Corner Joint

Objective Successfully solder two 45° brass corner joints. Equipment: DW-UHF-10kw induction soldering heater Materials StayBrite #8 silver solder supplied by customer Bridgit solder flux supplied by customer Brass corner joint Pancake coil Key Parameters Power: 5.5 kW Temperature: Approximately 550° F (288° C) Time: 20 sec

Process:

1. Flux is applied at all joints.
2. The assembly is positioned into for heating
3. Induction heating is applied for 15 sec
4. The brazing rod is applied to the joint

Results/Benefits:

1. Since the brazing alloy is manually fed, the coil is placed under the joint, facing the visible side of the frame. The visible side of the joint is laying on a flat wooden surface, which does not allow the brazing alloy to leak and spill. This keeps the visible surface nice and clean, while the seam is internally brazed.
2. If solder paste is used, then the coil can be placed on top of the joint. If special dual coil is used, then both joints (top and bottom) can be done with one shot.
3. No frame flipping is needed in this case. See the video and zoom the pictures attached for more details.
4. No special cleaning is needed on either side of the joint. The samples on the pictures have been paper towel wiped only.

https://dw-inductionheater.com/induction-soldering-brass-corner-joint.html?feed_id=239730&_unique_id=660c2e3872b24

Induction Soldering Wire To Aluminum Lug

Objective The objective of this induction soldering wire to aluminum lug in under 30 seconds. Equipment DW-UHF-6KW-III handheld induction soldering heater HLQ custom coil Key Parameters Power: 1.75 kW Temperature: Approximately 250°C (482°F) Time: 25 seconds

Materials Aluminum Lug Litz Cables

Induction Soldering Process: In order to start the induction soldering process, the aluminum lug was placed in the center of the coil. Then the litz wire was placed into the lug along with the solder. The solder started to melt after 25 seconds at approximately 250°C (482°F). After the solder was completely melted it was left to cool for one minute before proceeding.

Results: The tests were a success. We were able to prove that induction heating was a much faster method of induction soldering wire to aluminum lug rather than using a torch as the customer had done in the past. The application testing showed an increase in productivity and control over the time and temperature.

https://dw-inductionheater.com/induction-soldering-wire-to-aluminum-lug.html?feed_id=239392&_unique_id=660953289f1ad

Induction Soldering Brass to Steel Plate

High Frequency Induction Soldering Brass to Steel Plate Technology

Objective High Frequency Induction Soldering brass to steel plate Equipment DW-UHF-6KW-I handheld induction brazing heater

Materials Steel plate to brass part induction soldering using Harris Stay-Brite #8 Silver Bearing Solder and Harris Bridgit Lead Free Soldering Flux. Key Parameters Power: 2kW Temperature: 535°F to 585°F (279°C to 307°C) Time: 21 Seconds  

https://dw-inductionheater.com/induction-soldering-brass-to-steel-plate.html?feed_id=239227&_unique_id=6607e5b4e654f

Induction Soldering Cables to Terminals

Objective Induction Soldering cables to terminals in under 20 seconds using induction.

Equipment DW-UHF-6KW-I handheld induction heater Materials • 0.078″² (50mm²) cable terminal • 0.078″² (50mm²) cable • Soldering alloy Sn60Pb38Cu2 Key Parameters Power: 2.8 kW Time: 15-20 sec Temperature: 500° F (260° C)

Process:

1. The 0.078″² (50mm²) cable terminal is attached to 0.078″² (50mm²) cable
2. The assembly is positioned inside the coil and induction heating is applied.
3. Time to temperature is about 4 -5 sec. The temperature is maintained constant to complete the soldering process. A foot switch is used to start and stop the machine.
4. After 15-20 sec, the cable and cable terminal are successfully soldered.

Results/Benefits: Suitable induction heating systems for the process: DW-UHF-6KW-I handheld induction heater The DW-UHF-6KW-I handheld induction heater will require a longer time to reach temperature and complete soldering. Induction heating provides:

• Strong durable joints
• Selective and precise heat zone, resulting in less part distortion and joint stress
• Less oxidation
• Faster heating cycles
• More consistent results and suitability for large volume production, without the need for batch processing
• Technology without pollution, which is clean and safe

https://dw-inductionheater.com/induction-soldering-cables-to-terminals.html?feed_id=239091&_unique_id=660678285e759

Induction Soldering Coaxial Cable

Objective Induction Soldering coaxial cable to connector ring and pin in two steps in under 5 seconds by reaching a temperature of 500°F (260°C) with induction heating.

Equipment DW-UHF-6KW-III handheld induction heater Channel coil Materials • No-flux solder wire • Coaxial cable • Cable connector • Center pin Key Parameters Power: 3.0kW Temperature: 662°F (350°C) Time: 5 sec

Process:

1. The coaxial cable and connector were placed vertically inside the coil.
2. Induction heating was applied for 3 seconds, at which point the part is hot enough for soldering.
3. The induction soldering wire was fed between the cable braid and connector.
4. Solder wire was inserted into the center pin, and the center pin was placed in the coil.
5. The cable with connector was placed above the pin.
6. Induction heat was applied for 1.5 seconds, after which the part was hot enough for soldering.
7. The center conductor was inserted into the pin.
8. The assembly was inspected to ensure that the soldering was successful.

Results/Benefits:

• Strong durable joints and faster heating cycles
• Selective and precise heat zone, resulting in less part distortion and joint stress
• Technology without pollution, which is both clean and safe

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https://dw-inductionheater.com/induction-soldering-coaxial-cable.html?feed_id=235992&_unique_id=65ed79a0e0191

Induction Soldering Brass to Steel Plate

High Frequency Induction Soldering Brass to Steel Plate Technology

Objective High Frequency Induction Soldering brass to steel plate Equipment DW-UHF-6KW-I handheld induction brazing heater

Materials Steel plate to brass part induction soldering using Harris Stay-Brite #8 Silver Bearing Solder and Harris Bridgit Lead Free Soldering Flux. Key Parameters Power: 2kW Temperature: 535°F to 585°F (279°C to 307°C) Time: 21 Seconds  

Induction Soldering Copper Tap

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. https://dw-inductionheater.com/induction-soldering-copper-tap.html?feed_id=227951&_unique_id=6512f46d8ad53

Induction Soldering Cables to Terminals

Objective Induction Soldering cables to terminals in under 20 seconds using induction.

Equipment DW-UHF-6KW-I handheld induction heater Materials • 0.078″² (50mm²) cable terminal • 0.078″² (50mm²) cable • Soldering alloy Sn60Pb38Cu2 Key Parameters Power: 2.8 kW Time: 15-20 sec Temperature: 500° F (260° C)

Process:

1. The 0.078″² (50mm²) cable terminal is attached to 0.078″² (50mm²) cable
2. The assembly is positioned inside the coil and induction heating is applied.
3. Time to temperature is about 4 -5 sec. The temperature is maintained constant to complete the soldering process. A foot switch is used to start and stop the machine.
4. After 15-20 sec, the cable and cable terminal are successfully soldered.

Results/Benefits: Suitable induction heating systems for the process: DW-UHF-6KW-I handheld induction heater The DW-UHF-6KW-I handheld induction heater will require a longer time to reach temperature and complete soldering. Induction heating provides:

• Strong durable joints
• Selective and precise heat zone, resulting in less part distortion and joint stress
• Less oxidation
• Faster heating cycles
• More consistent results and suitability for large volume production, without the need for batch processing
• Technology without pollution, which is clean and safe

Induction Soldering Wire To Aluminum Lug

Objective The objective of this induction soldering wire to aluminum lug in under 30 seconds. Equipment DW-UHF-6KW-III handheld induction soldering heater HLQ custom coil Key Parameters Power: 1.75 kW Temperature: Approximately 250°C (482°F) Time: 25 seconds

Materials Aluminum Lug Litz Cables

Induction Soldering Process: In order to start the induction soldering process, the aluminum lug was placed in the center of the coil. Then the litz wire was placed into the lug along with the solder. The solder started to melt after 25 seconds at approximately 250°C (482°F). After the solder was completely melted it was left to cool for one minute before proceeding.

Results: The tests were a success. We were able to prove that induction heating was a much faster method of induction soldering wire to aluminum lug rather than using a torch as the customer had done in the past. The application testing showed an increase in productivity and control over the time and temperature.

Induction Soldering Wire To Aluminum Lug

Objective The objective of this induction soldering wire to aluminum lug in under 30 seconds. Equipment DW-UHF-6KW-III handheld induction soldering heater HLQ custom coil Key Parameters Power: 1.75 kW Temperature: Approximately 250°C (482°F) Time: 25 seconds

Materials Aluminum Lug Litz Cables

Induction Soldering Process: In order to start the induction soldering process, the aluminum lug was placed in the center of the coil. Then the litz wire was placed into the lug along with the solder. The solder started to melt after 25 seconds at approximately 250°C (482°F). After the solder was completely melted it was left to cool for one minute before proceeding.

Results: The tests were a success. We were able to prove that induction heating was a much faster method of induction soldering wire to aluminum lug rather than using a torch as the customer had done in the past. The application testing showed an increase in productivity and control over the time and temperature.