Induction Soldering Brass Heating Exchanger Of a Series Copper Pipe
Objective To solder a brass end cap to a series of copper tubes
Material Preassembled heat exchanger with copper tubes and 2 brass end caps 2.36” (60mm) OD, 0.08” to 0.12” (2 to 3mm) thick at both ends, liquid solder
Temperature 302ºF (150ºC)
482ºF (250ºC)
Frequency 237kHz
Equipment • DW-UHF-20kW induction heating system, equipped with a remote workhead containing one 1.0μF capacitor
• An induction heating coil designed and developed specifically for this application.
Process A dual four turn pancake coil is used to solder 2 brass caps per cycle. Liquid solder is squirted onto the end cap and is heated for 18 seconds at 302ºF (150ºC) to burn off the flux. Then the
heat is increased to 482ºF (250ºC) for 15 seconds to solder the parts.
Results
Induction heating provides:
• Even distribution of heating
• Compared to hot plate, induction heating is able to heat two parts in 30 seconds vs. one part in 60 seconds
• Increased production
• No discoloration with the slow heating process
Induction Soldering Brass Rings With High Frequency IGBT Induction Heater
Objective: To heat 1 3/4", 3" and 6" diameter brass slip rings and a sheathed copper wire assembly to 3600 F for soldering within three (3) to six (6) seconds. Currently production is accomplished by using a soldering iron and stick feeding rosin cored solder. This process leaves unwanted solder on the side of the slip ring where the soldering iron makes contact. The customer would like to see an increase in joint quality without sacrificing time.
Material: 303 Brass Slip Rings of 1 3/4", 3" and 6" diameters. Sheathed Copper Wire Assembly.
Resin Core Solder, 37% Pb, 63% Sn.
Temperature: 3750F
Application: Through laboratory testing, the DW-UHF-20kW output solid state induction power supply along with a unique four (4) turn "ear muff" type coil produced the following results:
Times to reach 3750 F are as listed below:
- 1 3/4" in 3 seconds
- 3" in 3-4 seconds
- 6" in 5 seconds
Adequate solder flow was observed producing a clean joint.
Solder preforms are recommended to speed up production.
Side loading was facilitated by the unique four (4) turn "ear muff" style coil.
Equipment: DW-UHF-20kW output solid state induction power supply including one (1) remote heat station containing one (1) 1.0 μFcapacitor, a 4-20mA input for fast ramp simulation, and a unique four (4) turn "ear muff" style coil.
Frequency: 265 kHz
Induction Soldering Brass Assembly With High Frequency Soldering Units
Objective: To heat a brass bellows and end cap assembly to 4500F for soldering within 20 seconds. Presently, a soldering iron is used to produce the joint between the bellows and cap. The customer requests a quality solder joint with minimal heating of the bellows to prevent annealing and performance losses. Solder preforms, in the form of flat washers, are to be used to complete this application.
Material: Brass Bellows measuring 2" in diameter Solder Preforms
Cadmium Free Flux
Temperature: 4500F
Application: The DW-UHF-20kW output solid state induction power supply along with a unique three (3) turn double wound helical coil was utilized to achieve the following results:
4500F was reached and solder flow completed in 6.3 seconds.
A quality repeatable solder joint was observed.
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 double wound helical coil with an inside diameter of 0.4".
Frequency: 307 kHz
Induction Soldering Brass Tube-Pipe-Tubing With RF Soldering Heating System
Objective: Soldering two brass tubes measuring 3/4" and 1/4" together for use as cellular phone antennas. The lengths of tubes range from four (4) feet to twelve (12) feet, and must be soldered along the axial side. The joint is to be made using 60/40 Tin Lead Solder and Kestor Rosin paste flux.
Material: Brass Tubes measuring 3/4" and 1/4" 60/40 Tin Lead Solder
Kestor Rosin Flux
Temperature: 3750F
Application: Through the use of the the DW-UHF-40KW output solid state induction power supply along with a unique five (5) turn 12" long channel coil, the following results were achieved:
3750 F was reached and the solder flowed after a heating period of 35 seconds.
A production rate of 24" per minute was determined to be adequate.
A quality solder fillet was observed after heating and cooling
Equipment: DW-UHF-40kW output solid state induction power supply including one (1) remote heat station containing two (2) capacitors, and a unique five (5) turn channel coil made from 3/16" copper tubing and measuring 1 1/4" by 12".
Frequency: 385 kHz
Induction Soldering Brass Heating Exchanger Of a Series Copper Pipe
Objective To solder a brass end cap to a series of copper tubes
Material Preassembled heat exchanger with copper tubes and 2 brass end caps 2.36” (60mm) OD, 0.08” to 0.12” (2 to 3mm) thick at both ends, liquid solder
Temperature 302ºF (150ºC)
482ºF (250ºC)
Frequency 237kHz
Equipment • DW-UHF-20kW induction heating system, equipped with a remote workhead containing one 1.0μF capacitor
• An induction heating coil designed and developed specifically for this application.
Process A dual four turn pancake coil is used to solder 2 brass caps per cycle. Liquid solder is squirted onto the end cap and is heated for 18 seconds at 302ºF (150ºC) to burn off the flux. Then the
heat is increased to 482ºF (250ºC) for 15 seconds to solder the parts.
Results
Induction heating provides:
• Even distribution of heating
• Compared to hot plate, induction heating is able to heat two parts in 30 seconds vs. one part in 60 seconds
• Increased production
• No discoloration with the slow heating process
Induction Soldering Brass Connector In Solar Panel With IGBT Induction Heater
Objective Solder three brass connectors one at a time in a solar panel junction box without affecting the components in the junction box
Material Solar panel junction box, brass connectors, solder wire
Temperature 700 ºF (371 ºC)
Frequency 344 kHz
Equipment • DW-UHF-6 kW induction heating system, equipped with a remote workhead containing one 1.0 μF capacitor.
• An induction heating coil designed and developed specifically for this application.
Process A three turn oval shaped helical coil is used to heat the connectors. A piece of solder wire is placed onto the joint area and each joint is heated separately for 5 seconds to solder the connector. The total process time is 15 seconds for the three joints.
Results/Benefits Induction heating provides:
• Pinpoint accuracy deliver heating only to joint; does not affect surrounding components
• Localized heat produces neat and clean joints
• Produces high quality, repeatable results
• Even distribution of heating
