Induction Heating a Tube to Heat Gases
To heat an Inconel tube with a custom-designed multiple-turn helical coil for a gas heating application
Heating Copper Parts for a Burn-Off Application
To heat copper parts, which are battery lugs, for a burn-off application.
Preheating Steel Tubes Prior to Bonding
To heat steels tubes for a bonding application; the end product is a bushing for large trucks. Induction would replace an oven for this client.
Heating a Copper Wire for Coating Removal
A custom-designed multiple turn helical coil was built to generate the required heating for this coating removal application.
Heating a Steel Pan to Evaporate Water
A multiple turn pancake coil was designed to provide heat to the base of the steel pan. Initial tests were conducted to optimize the power delivered to the part and to understand the heating patterns
Brazing a Copper Tube and Brass Fitting Assembly
To heat a customer supplied copper tube and brass fitting assembly for a brazing application; the customer, a manufacturer of heat exchangers, had been manually brazing the assemblies.
Brazing Steel Assemblies (hydraulics)
A custom-designed single position multiple-turn oval split helical coil was built to generate the required heating for this brazing application.
Heating Stainless Steel Assemblies to Remove Glass
A custom-designed single position multiple-turn helical coil was built to generate the required heating for the application. Initial tests were conducted to optimize the power delivered to the part.
Brazing an Aluminum Tube Assembly
A custom-designed single position multiple-turn pancake coil was built to generate the required heating for this brazing application. Initial tests were conducted to optimize power delivery to the assembly
Heating Steel Assemblies for Sealing
A single position multiple-turn pancake shaped coil was built to generate the required heating for the application. Initial tests were conducted to optimize the power delivered to the part.
Heating a Flanged Part Before Welding
A custom-designed single position multiple-turn oval coil was built to generate the required heating for the preheating application. Initially, a helical coil design was used which did heat the part faster, but the pattern wasn’t uniform.
Brazing a Carbide and Steel Assembly
A custom-designed single position multiple-turn helical coil was built to generate the required heating for this brazing application. Initial tests were conducted to optimize power delivery.
Brazing Copper Tubes for a Solar Industry Application
A custom-designed single position multiple-turn split-helical coil was built to generate the required heating for this brazing application.
Heating a Steel Susceptor for Glass Cutting
A custom-designed single position multiple-turn helical coil was built to generate the required heating for the application. Initial tests were conducted to optimize the power delivered to the part.
Brazing FishhooksA custom designed single position multiple-turn helical coil was built to generate the required heating for the application.
Heating Non-Magnetic Steel Tubing
To heat non-magnetic steel tubing for an application in the energy storage market.
Brazing Copper BussbarsA custom-designed single position multiple-turn helical coil was built to generate the required heating for the application.
Heating Surgical Tools for Coating Burn Off
To heat surgical tools to burn-off the nylon coating; the client had been using a torch for this application. Within seconds of the power being turned on, the coating on the tool began to smoke and soon started to bubble.
Heating Steel Cutting Tools for Carbide Removal
Using induction to heat magnetic steel cutting tools for removal of carbide cutting tips. Induction efficiently and precisely heats the client's part in a controlled manner delivering only the required heat.
Brazing a Copper Tube & Brass Fitting
A custom-designed single position multiple-turn U-shape coil was built to generate the required heating for this brazing application.
Heating Steel Coated Copper Wire
In static tests, it was observed that it took 2.5 seconds to heat an 11” (279 mm) length of sample wire to target temperature.
Brazing Copper and Brass Valves
To braze various copper and brass assemblies for a valve manufacturer; they are looking to replace their torch heating process with induction
Brazing Steel Fittings & Tubes (Hydraulics)
Braze steel fittings and tubes in an atmosphere to make hydraulic fittings within a targeted heating time of under 150 seconds.
Heating Steel Shafts for Forming (Medical Tools)
A custom-designed single position multiple-turn helical coil was built to generate the required heating for this application.
Heating Graphite DiscsA custom-designed single position multiple-turn pancake coil was built to generate the required heating for this application.
Brazing Both Ends of a Steel Assembly
The client wanted to braze both ends of the part concurrently within their time requirements. Induction met the client’s time requirements and is often faster than other heating methods. With induction there is no open flame and with induction’s instant on/off capabilities, it introduces less heat into the work environment.
Heating Steel Pipe for a Casting System
The client wants to replace their resistive steel pipe heating process; it takes 15 minutes to reach the desired temperature.
Brazing Copper and Brass Fittings (Flange)
How to braze copper tubes and a steel plate for a brazing application; while this is a new process for the client, they also tested the process with a torch
Steel Nozzle Assembly (Aerospace)
Where you can struggle with repeatability with an oven and torch, induction brazing is a more repeatable process. With induction heating, there is no open flame and the benefit of instant on/off capabilities. This introduces less heat into the work environment.
Preheating Parts for WeldingInduction dramatically reduced the heating time they saw with torch heating as it dropped from 20 minutes to 3 minutes
Brazing Brass and Copper Nozzles
To braze copper and brass samples for an application in the aerospace industry, induction heating was used in place of a previously used torch. Induction brazing allows more consistent, higher quality parts.du
Heating Steel Knives; Food Processing
To rapidly heat steel knives on the line of a food processing facility, improving efficiency; the client had been using a different heating method.
Brazing a Steel Part for the Aerospace Industry
A custom-designed multiple-turn helical coil was built to generate the required heating for a steel cable for the aerospace industry. Induction brazing was used to heat a steel part for a brazing application.
Drying Steel Rings with Induction Heating
To heat streel rings for a drying application; the client was using hot air but it wasn’t completely drying the rings
Brazing, De-brazing Carbide, Steel Plates
A custom-designed special multiple-turn helical coil was built to generate the required heating to heat a carbide and steel plate assembly for a brazing and de-brazing application in the oil and gas industry.
Preheating Rod Assemblies for Welding
The client had been using torches for preheating. However, due to process improvements thanks to new automation in their facility, torch heating became too slow. This resulted in a backlog that kept them from maximizing their throughput.
Brazing Brass Assembly; Sink Manufacturer
To heat brass assemblies for a brazing application, the client, who manufactures sink products had been using a torch. Induction heating heated the assembly to temperature and better met the client’s time requirements.
Induction Preheating Steel Laminate Parts
The c-lams are inserts for an automotive industry application. In production the robotic pick-and-place will occur for plastic overmolding after heating by induction.
Brazing a Copper Tube and Steel Plate
In order to braze copper, a custom-designed single position multiple-turn helical coil was built to generate the required heating for the tube-to-plate brazing application. Initial tests were conducted to optimize the power delivered to the part. Repeatability was a top priority for this client.
Heating Busbars for Coating Release
Induction’s precision heating enables the part to heat to the exact targeted temperature, which prevented melting of the tin-coated copper part
Heating Automotive Battery Cables for Adhesive Melting
Temperature indicating paint was applied to the parts, and it took 10 seconds to heat the various styles of the part to the targeted temperature. This testing achieved the client's time and quality objectives.
Brazing a Nickel Pin and a Nickel Wire
A client had been using flame heating to braze a nickel pin and a braided nickel wire. The end-product is a heater assembly. Using induction improved joint quality compared to using flame heating.
Heating Lighting Tubes for Getter Firing
The getter firing application was complete within just 10 seconds. Induction delivers the same result time after time, making it ideal for their high-volume manufacturing process
Brazing a Carbide Tip and Magnetic Steel Tube
To braze carbide inserts into magnetic steel tubes, an inconsistent torch process was replaced with induction brazing equipment. In this application, quality rather than speed was the top priority.b
Heating Wires and Strips for Coating Removal
The polymer coating on the aluminum strip behaved differently when heated. Visually, the coating turned brown and bubbly when the aluminum strip was heated
Brazing a Steel and Carbide Assembly
To braze a steel and carbide assembly to create a mining bit for the oil and gas industry, this client replaced their torch process with the repeatable and flameless induction brazing technique.
Braze a Copper Tube and Brass Fitting (fuel containment)
How to braze copper using a custom-designed single position multi-turn helical coil built to generate the required heating for the copper brazing application.
Heating an Aluminum Tube for Bending
Induction does not present an open flame into the work environment like a torch, resulting in a safer working environment
Brazing a Copper Strip Assembly
The client requested a system that would meet their time objectives which the EKOHEAT easily did, boosting the client's throughput.
Heat a Fixture for a Wire Heating Application
Heat a non-magnetic metal alloy shape-setting fixture for a Nitinol wire heating/shaping application.
Induction brazing a Steel Tube with External Wire Braid
The coil selected is not only capable of induction heating the steel 7/8/22 mm tube, but also a smaller tube that the client needs to heat.
Heating a Tube Prior to Swaging
With the process designed by Ambrell's applications engineers, the tubing heated to temperature within five seconds. This result met the client's objective
Brazing, De-Brazing Diamond Carbide Inserts
Heat steel cutting bits with diamond-carbide inserts for brazing and de-brazing; the end products are cutting tools
Preheating a titanium alloy wire prior to welding
With an EKOHEAT 10 kW power supply, the titanium alloy wire can be heated to 2732 °F (1500 °C) in three seconds. This testing configuration simulates using three EASYHEAT 10 kW power supplies in series.
Brazing a steel and carbide dental assembly
This configuratoin achieved the client's objective. The channel coil - specially designed by THE LAB at Ambrell- was critical to the application's success.
Brazing a brass tube and flange; torch replacement
Application engineers determined placing a turn that is targeted to the tube inside the part would optimize heating for this application. This heats the tube while the flange is being heated enabling both parts to achieve the required temperature concurrently.
Brazing a magnetic steel cutting tool with induction
Induction heating rapidly heats the steel parts to the required temperature, especially with the EKOHEAT's Auto Tap feature. The Ambrell Applications Lab used their expertise to create the right solution for the system and the system hardware.
Heating a cutting knife, improving cut
In this example, induction heating provides consistent, repeatable results, a safe, reliable source of heat, measurable & stable results and less production scrap
Preheating a magnetic steel die
The induction process required 10 minutes to heat to the required temperature; the client's resistance heater took more than ten minutes. Also there will no longer be a need to open the chamber to remove the heater.
Brazing a steel and copper strip to carbide
Induction heating of the steel took less than 30 seconds, is highly repeatable and there is no open flame, clear benefits over flame heating. it a safer method of heating than torch heating
Heating aluminum wire to create screens
Induction will double production due to more rapid heating than infrared lamps can offer; with induction 100 feet per minute can be run instead of 50 feet per minute with infrared
Induction brazing a rectangular steel part
Induction heating of the steel took 30 seconds (or less), which can't be matched when using a torch. This client was using an old induction system from another vendor, and the Ambrell system provided considerably faster heating
Heating rods for thread rolling to create fasteners
This is part of an automated line. The system was sized and the coil was designed to ensure 45 parts per minute can be heated to the temperature required for hot forming.
How to braze a copper tubeThe client had been using a torch, which took 50 seconds instead of 30; induction brazing the copper increased repeatability and in turn boosted part quality. Also, there is no open flame which makes it a safer method of heating than torch heating
Induction heating stainless steel inserts for an insertion application
Induction heating offers dramatically faster heating compared to ultrasonics which means dramatically increased production rates. Induction is highly repeatable and easy-to-integrate into manufacturing processes.
Copper block & carbide; contact assembly
Induction completed the carbide brazing process more rapidly than an oven, delivering heat exactly where it's needed, operating instant on/instant off
Hot forming a steel pipe with induction
A 2.5 inch steel pipe is heated by induction to the targeted temperature quickly with induction's repeatable process. EKOHEAT is easy to integrate into manufacturing processes and targets only the portion of the tube that requires bending while not heating the remainder of the tube.
Induction heating steel coupons and carbide cutters for brazing and de-brazing
The first coupon that was heated had a 16 mm (0.63) diameter cutter, so removal of the cutter was the objective. The part was coated in black flux and inserted into the coil...
Brazing aluminum adaptors to the end of aluminum tubes
To increase production, a multi-position coil was recommended so multiple parts could be heated while maintaining a cycle time of 55 seconds, delivering consistent joint quality, which a torch often doesn't deliver.
Induction heating a steel grenade for a disposing application
The grenade was then placed inside the coil and power was turned on. After just two seconds the painted indicated, meaning the part achieved 800 °F (427 °C).
Brazing a nickel sleeve to a copper mast
To heat a nickel sleeve and a copper mast for a brazing application to create a pitot tube for the aerospace industry
Tempering an audio speaker screen
The speaker screen was placed over the induction coil and the power was turned on. The screen heated to the desired temperature within just one second
Brazing a brass screw cap and a steel tube
Induction heating enables brazing the cap and tube to be completed at a rate of 15 seconds per part while delivering consistent joint quality in a safer environment which a torch often can't offer...
Brazing a stainless steel fitting to a stainless steel capillary tube
Induction enables consistent joint quality in about 35 seconds, which a torch often doesn't deliver; in this case this is the primary reason for switching to induction
Heating an aluminum-backed circuit board to reflow solder
Given the significantly faster heating time, induction improves throughput in this process and is a more efficient heating method than hot plate heating
Heating a Kovar tube for a glass sealing application
The client was using a torch, and operator error was slowing the heating. The repeatability of induction enables improved throughput while in this process it is a more efficient heating method than torch heating, also reducing scrap
Brazing a steel coupler and a steel wire
Induction heating enabled the brazing process to be completed within 30 seconds. The client was using a torch, and induction offers superior repeatability with no open flame and delivering heat only where it's required...
Heating a chromel grid for an oxidization application
Induction delivers a dramatic reduction in heating time, enabling a significant increase in production while providing a more energy-efficient heating method than furnace heating
Induction Pre-heating a steel transaxle tube for a welding application
Induction heating achieves an identical result consistently, and is a more efficient heating method, each of which are advantage over torch heating
Brazing brass tube and fitting assemblies
The brass tubes and fittings heated to required temperature far more quickly than with customer's torch method, resulting in improved part quality and introducing less heat into the production environment...
Pre-heating a steel plate and a carriage roller shaft with induction for a welding application
Induction heating achieves the client's targeted speed/production rate and opens up the possibility of preheating while welding
Brazing carbide tips to a steel cutter
The cutter was held in a vice and the coil was presented to heat the assembly. A ceramic rod was used to press the carbide tip onto steel cutter during brazing.
Heating fluid passing through an alumina tube
To heat an alumina tube to heat magnetic particles in order to heat fluid passing through the tube for an oil industry application
Brazing a copper tube assembly
The proposed system is capable of heating a wide variety of tube assemblies, is light enough to be used on a cart and is able to meet the client's time/productivity objectives
Heating the joint area of two lead plates for a butt welding application
The client was using a torch, which took five minutes; induction takes just one minute, which means an improved production rate and, unlike a torch, induction heating is precise and repeatable...
Brazing a brass tube assembly (valve manufacturing)
With the recommended coil configuration, the cycle time turned out to be 25% less than what the client was targeting, resulting in increased production efficiency; a good braze joint was formed, and induction's consistency and repeatability proved valuable
Induction heating cylinder liners for insertion into aluminum engine blocks
Temperature indicating paint was applied to the steel part for testing purposes. The part was then placed into the induction heating coil and the power was turned on. In just under 30 seconds, the part achieved temperature.
How to braze three copper tubes to create a four-way valve
Due to the use of a higher power system, speed expectations were exceeded and improved over the client's previous method, which was torch heating. A good copper braze joint was formed, and induction's consistency and repeatability proved valuable. Induction brazing doesn't employ an open flame, which results in a safer work environment
Heating stainless steel finned parts
Induction is a targeted, precise heating method with instant on/off, saving users energy and it is a flameless heating method, so it provides employees with a cooler, lower-risk working environment...
Brazing copper tubes to a brass manifold block
The proposed process met the client's time objective, and is faster than oven heating.
Heating a coated copper wire for a stripping application
The top 1 (25 mm) portion of the plastic coated wire was placed inside the helical coil and heating began. The top turn rapidly started to heat and the plastic melted after about 10 seconds of heating...
Brazing copper and brass valve assemblies (HVAC)
The copper tube (1/8/3.2mm) is inserted into the flared copper tube (1/4/6.4mm). Two braze rings are placed on the copper tubes and the power is applied....
Heating a copper end cap to temperature to melt wax
To heat a copper end cap to temperature for a wax reflow application; the end product is a temperature stat and the client is looking to cut their heating time in half...
Brazing steel drill bits (aerospace)
The client wanted to heat three parts concurrently, and this process allowed up to five parts to be heated concurrently...
Preheating copper barsTo preheat two copper bars to temperature within 30 seconds; the client is looking to replace a competitor's 5kW induction heating system that is delivering unsatisfactory results
Brazing steel flange and shaft assemblies (aerospace and automotive applications)
Induction brazing is a repeatable process that isn't as labor intensive as a flame often is. The process can heat the assembly rapidly and more energy-efficiently than a torch without the safety risks that come with an open flame
Brazing two fittings and a helical tube to create a mount
The client had been using a torch, and was dealing with inconsistent results that impacted part quality. Induction heats the assembly more quickly than the torch..
Heat steel plates of various thicknesses with induction on the same line
This in-line system enables the client to heat plates with significantly different thicknesses, while the feed-rate varies considerably based on the thickness of the part. Induction is the fastest method of heating steel plates to the required temperature
Brazing tubes and fittings for an air conditioning unit for the off-road market
Clients were using an oven, and because the whole part was being heated and essentially annealed, it created problems with the part. Induction only heats the braze area, and resolves that issue...
![Preheating a copper rod and connector [epoxy curing]](https://www.ambrell.com/hs-fs/hubfs/ambrell-images/Applications/Thumbs/heating_77.jpg?width=95&height=95&name=heating_77.jpg)
Preheating a copper rod and connector [epoxy curing]
Induction heated the part to temperature quickly in a far more efficient method than an oven, heating only the parts of the rod that required heating
Brazing a steel and brass immersion heating element
Induction results in faster heating than a torch with faster, multipart heating to increase output...
Heating a titanium bracelet; create the desired finish
Within 35 seconds the center band of the bracelet turned black. The client had been using a torch, but looked to induction due to speed, safety and repeatability...
Brazing an aluminum assembly for a bicycle manufacturing application
For this aluminum bicycle tube brazing application, induction heating delivers more repeatable and consistent results, while cutting client's heating time in half when compared to using a torch...
Preheating a titanium billet to temperature prior to rolling
Induction uniformly heats the large billet and the client's longer 15 foot billets quickly to 1800C.
Brazing a magnetic steel tube and steel mating assembly
Heating a 0.437 (11.1) in(mm) outside diameter magnetic steel tube and steel mating assembly to temperature for a brazing application to create an oil tube for the railroad industry...
Heating a nanoparticle solution to 40 °C
Heat a nanoparticle solution to get it to increase at least 40 °C for medical research/laboratory testing
![Brazing an aluminum manifold [air conditioning]](https://www.ambrell.com/hs-fs/hubfs/ambrell-images/Applications/Thumbs/brazing_74.jpg?width=95&height=95&name=brazing_74.jpg)
Brazing an aluminum manifold [air conditioning]
Precise, repeatable heating: The client wanted more precise and repeatable heating than a torch could deliver, which induction was able to achieve..
Stress relieving flat blanks of carbon steel to reduce wheel hardness
Induction rapidly heats the carbon steel to temperature, enabling a rate of 30 feet per minute, not only saving production time, but saving energy costs. With a modest footprint, induction is easily implemented into production processes such as this one...
Brazing a steel tube and fitting to create an automotive valve
Customer's client was unhappy with the results from MIG welding, which drove them to look at induction as an alternative process. Induction heating proved to be a fast, repeatable heating method for the application...
Heating an Inconel tube (incineration)
Induction offers uniform heating, which flame does not offer, is more efficient than flame and can rapidly melt the materials
Brazing a carbide ball to a spring to create a part that controls the armature position in a motor
To heat a tungsten carbide ball and steel rod that acts as a spring to 1300 °F (704 °C) within five seconds for a brazing application to create a part that governs the armature position in a motor...
Induction preheating a turbine blade (welding)
The end result is a preheating process that allows the part to move quickly to the welding step while meeting all quality requirements
Brazing a steel rod and sensor housing assembly
To heat a steel rod and housing to 1400 °F (760 °C) within 30 seconds for a brazing application to create an assembly for a sensor...
Heating a steel ball on a pin by induction for an insertion application
While the project is new, the customer wanted the steel part to be heated to temperature within four seconds, and that was easily achieved and exceeded with the EASYHEAT power supply
Heat a steel block with a cutout for carbide for a brazing application
Induction delivers improved quality and repeatability; client was using a torch and induction offered more precise, repeatable heating. In addition, this allowed the client to achieve the targeted heating time of 60 seconds, faster than what the torch could deliver...
Induction preheating steel rods for a welding application
Induction heating does a superior job penetrating the pin when compared to a torch, which is critical to preheating for welding and enables fast heating which can boost production compared to torch heating
Brazing a copper elbow tube assembly
In this copper brazing process, induction offers more precise, repeatable heating than current flame process...
Induction preheating a steel automotive transaxle (welding)
The steel axle was painted with temperature indicating paint and a thermocouple was attached to the part.
Brazing copper tubing and brass fittings for aerospace parts
Induction heating achieves superior process repeatability when compared to a brazing torch and a more predictable aerospace parts which enhances quality..
Heat a block of Haynes nickel alloy to test the crack growth rate
Testing was conducted to optimize the power delivered to the part. The coil was designed to minimize the voltage potential over the length of the part.
Brazing a steel tube and fitting assembly
Induction heating is used to braze a steel connector onto a steel tube to create a hydraulic component. ...
Induction preheating a steel plate for forging
The induction heating process achieved a production rate of 100 steel parts per hour, while a gas furnace produced 83 parts per hour; the process is repeatable and can be integrated into a production process
Brazing stainless steel medical tool parts into a coupling
Induction heating is used to achieve client's goal to braze both stainless steel parts as quickly as possible with maximum repeatability...
Brazing steel tube fittingsA tube assembly is heated to the desired braze temperature in 20-25 seconds, which achieves the client's targeted cycle time of less than 30 seconds...
Brazing a magnetic steel rotor assembly
Induction is proposed to replace a hand-operated flame process requiring operator training and expertise. Induction heating delivers a precise, repeatable and reliable process. Improved joint quality is coupled with simplified operation...
Induction Heating Tool-Steel Circular Dies to 400C in 10 minutes
Induction heating delivers heat directly into the steel part, saving energy and time, can be easily integrated with a press, presents a greatly reduced footprint compared with oven, batch, carts
Brazing carbide insert to steel pipe gripper chuck
Induction heating is proposed to braze carbide inserts into steel blocks in the assembly of pipe gripper chuck. To replace a hand/flame process, delivering significant reduction in per-part cycles...
Hardening steel pipe segments (sleeves)
Disappointed with low quality levels in a previously outsourced process, the customer uses induction to bring the heat treatment and the control of the end-product quality in-house.
Brazing a copper pipe assembly seam
The customer is seam brazing copper pipes together. They will reduce the brazing of the seam down to 15-30 seconds.This customer is currently using a torch, but is not getting uniform quality
Heating a steel wire for tempering
Induction heating delivers heat directly into the wire, saving energy and time, easy integration into production line, improving throughput, precise control of heat and even distribution of heat within the wire
Brazing a pressure switch base assembly
Induction heating provides hands-free heating that involves no operator skill for manufacturing, even distribution of heating precise and controllable heat
Preheating aluminum flangesInduction heating delivers higher quality end product vs. using an open flame convection furnace. Ovens are sensitive to ambient temperature and humidity variations and tend to produce uneven results
Brazing brass and steel for valves and end plugs
The customer is currently using a torch to complete the braze joints. They wish to improve repeatability for a better process.
Desoldering Customer Assemblies with Induction Heating
To heat customer assemblies for a desoldering application. The client had been outsourcing this task, but wanted to see if it would be viable to bring the process in house.
Heating a 4 Tubular Carbon Susceptor to 5400 °F (3000 °C)
A tubular carbon susceptor is held within an atmospherecontrolled quartz chamber. Induction is used to heat the susceptor
Brazing temperature sensor assemblies
A five-turn two-position helical coil is used for this brazing application. Each coil acts individually and the coils are not designed to heat simultaneously...
Soldering Brass and Copper Components
A solder wire preform was placed on the part to allow for repeatable placement of solder in every joint. Four top or four bottom joints will be heated at one time within 2-3 minutes for the soldering application.
Pre-heating aluminum wheels prior to spray painting
This spray painting application requires pre-heating the material. Additionally, there is a requirement that the material must not cool below a certain target temperature prior to the spray.
Heating a Copper Assembly for Soldering
To heat a glass feed-through inside a copper block for a soldering application, one side at a time. This was a new application/process for the client.
Heat an Inconel tube for a swaging application
A need to increase volume and quality of parts production led to the choice of an induction process over flame. Handling is minimized and continuity is assured with the precision delivery of heating only where required.
Brazing Copper Tubes to a Braided Stainless Steel Hose
Customer is currently using flame and a highly paid operator to complete this application. With an induction system, the customer can save approximately $20,000/year in operator cost alone, not factoring in any energy savings.
Soldering Ferrule and Module Assembly
To heat ferrule and module assemblies for a soldering application in the fiber optics industry.
Heating iron oxide (Fe3O4) nanoparticles in an aqueous solution for research
An eight turn helical coil is used to heat the vials. 0.0625 thick insulation is wrapped around the vial and the vial is placed in the coil. The optical temperature probe is inserted into the vial with the base of the probe located in the middle of the coil turns.
Brazing two aluminum pipes to an aluminum evaporator core
The customer is replacing a flame process which can burn away the thin flange at the joint area and create scrap parts. By switching to induction for this application the customer is decreasing their scrap parts and also increasing their quality and production rate...
Soldering Co-axial Wire to a Metal Frame
Given the small size of the part and the assembly's geometry, a graphite cylinder was required as a susceptor.
Heating a pin assembly to cut holes in a rubberized material
Induction heating provides precise and consistent application of heat, consistent and repeatable results, hands-free heating that involves no operator skill for manufacturing
Brazing brass bellow assemblies for pneumatic regulators
Customer is replacing flame with induction to braze/solder these parts. While they are not looking to increase their production, they are looking for a repeatable and reliable process...
Heating a Kovar Ferrule for Glass Soldering
The solder formed a relatively uniform domed seal around the fiber despite the asymmetry of the open C coil. It took under 10 seconds to heat the part to soldering temperature
Preheating a molybdenum anode for stress relief
A four turn helical pancake coil is used to heat the anode. The area on the anode to be preheated is the weld between the tube and flange.
Brazing a stainless steel shaft to a carbide for a digger used in mining
A three turn helical coil is used to braze the carbide to the shaft. The steel shaft is fluxed and the braze shim placed on top. The carbide tip is fluxed and placed on top of the shim, lining up the countersunk hole in the carbide. The hole is not fluxed because the flux outgases and causes the carbide to build up pressure and attempt to repel from the shaft...
Soldering Four Fusible Copper Strips
Soldering with Induction takes under 10 seconds to heat four copper strips concurrently, resulting in a boost in throughput for the client. Induction is a highly repeatable process that heats just the area of the copper strip that requires it
Heating a steel chain for tempering
A twenty turn helical coil is used to heat the chain. The chain is fed through the coil at a rate of 1 meter per minute to reach the desired 1760 °F (960 °C) for the tempering process.
Brazing a small gas delivery assembly used to manufacture needles
This is a new part for the customer and they are developing the manufacturing process for it. The customer is interested in using induction heat for their process because they are looking for finished parts which are clean and not contaminated by any flux material. By using induction to braze the part and by doing the braze under a hydrogen atmosphere, the customer can produce brazed parts with no oxidation...
Soldering a pair of magnetic steel pins
Soldering with induction required under 10 seconds and is a highly repeatable process; the customer can expect the same result every time with only the portion of the part requiring heating being heated.
Heating top of aluminum oxygen tank for end forming
Through heating the top 2 (50.8mm) of aluminum oxygen tank to form a rounded end with a hole for oxygen valve
Brazing copper and steel tube combinations for refrigeration and air conditioning
Customer is currently using flame brazing in a large facility for this application and will gain safety benefits with induction such as no hazardous fumes or open flames...
Soldering a rivet onto a steel tank cap with induction heating
Soldering with induction proved faster than the client's previous heating torch process. It is also is a repeatable heating process, so the client gets superior results and is more energy efficient than torch heating.
Preheating steel bar stock to forge a hot formed u-bolt
A fifteen turn helical coil with ceramic insert is used to preheat the 15 (381 mm) section of steel bar stock.
Brazing a spray bar assembly used for powder coating
Customer is currently outsourcing this application. By bringing in-house they will save on inventory build-up, transportation cost, time-to-customer and money. Customer found Ambrell on the web and liked the idea that Ambrell's application lab can prove capability before purchasing.....
Heating a steel tie down assembly to loosen steel pin for rotation
Induction heating provides precise and accurate placement of heat without affecting surrounding areas, much faster process time, from hours to minutes, repeatable and consistent results and even distribution of heating
Brazing vertical copper bars to a copper slip ring for refurbishing large motor assemblies
A three-turn helical coil is used to heat the slip ring. Power is applied for 25 minutes to bring the ring up to brazing temperature. The slip ring is then held at temperature as the self locating 52 vertical bars are brazed into place...
Soldering copper tabs for stringing, tabbing solar panels
Induction's precision soldering ensures repeatable results and less damage to surrounding substrates while demonstrating reduced heat loss and lower energy usage...
Heating a carbon steel plate with a tin coating for flow-melting
A nine turn Dog Bone style coil is used for the flow-melting process. The tin coated carbon steel plate is placed in the coil for 1.34 seconds to uniformly reflow the tin coating.
Brazing copper cable and block assembly for generator repairs
A three-turn helical combination channel coil is used to heat the assembly. The assembly is placed in the coil with a thin ceramic paper placed between the coil and copper assembly...
Soldering electrical wire to a copper grounding
For this grounding lug soldering application, induction delivers consistent result is achieved each time and does not present a flame, so it helps create a safer, cooler working environment than other methods
Preheat steel for reformingInduction heating provides controllable heat pattern, ease of on site location use, safe, no open flames and even distribution of heating
Brazing aluminum electrical lug assembly
A five turn helical coil is used to braze the assembly. The parts are assembled and placed in the coil. Power is applied and a braze stick is used to braze the two parts in 25-30 seconds...
Soldering brass and steel radiator caps
The induction soldering process is completed within 15 seconds with consistent results without the use of flame, creating a safer, cooler working environment...
Preheating steel garden tools for press stamping
Induction heating provides hands-free heating that involves no operator skill for manufacturing, configurable heating profiles, faster process times and even distribution of heating
Brazing a stainless steel shaft to a carbide cone for a gripper
A three-turn helical coil is used to braze the carbide to the stainless steel shaft. A silver solder washer is placed over the post on the shaft, the carbide is placed on the washer and flux is applied...
![Soldering a copper tube to a brass valve [flow valve]](https://www.ambrell.com/hs-fs/hubfs/ambrell-images/Applications/Thumbs/soldering_46.jpg?width=95&height=95&name=soldering_46.jpg)
Soldering a copper tube to a brass valve [flow valve]
The heating process was completed within 12 seconds, faster than the client's gas torch and more reliably. Without flame, induction helps create a safer, cooler working environment.
Heating lead battery terminal for removal (recycling)
A single turn helical coil is used for this heating application. The lead terminal is placed inside the coil and is heated for 20 seconds.
Brazing a copper pivot assembly
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...
![Soldering a copper wire, contactor assembly [motor]](https://www.ambrell.com/hs-fs/hubfs/ambrell-images/Applications/Thumbs/soldering_45.jpg?width=95&height=95&name=soldering_45.jpg)
Soldering a copper wire, contactor assembly [motor]
High intensity heat must be applied to the joint area for this application so that thermal conduction of the copper does not sink away the heat delivered from the induction process.
Heating a steel pipe to transport melted magnesium
Induction heating provides controllable and repeatable heat pattern that keeps material in liquid form, the technology is environmentally friendly, delivering even distribution of heating . The movable workhead can be located away from the power supply
Brazing brass faucet assemblyA 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...
Annealing Stainless Steel Braids
A specially designed multiple-turn helical coil was used to generate the required heating for the application. Initial tests were conducted to optimize the power delivered to the part.
Brazing a steel piston valve assembly
A five turn pancake coil is used to braze the piston valve and steel plate. The assembly was heated for 10 minutes to flow the braze and join the two pieces...
Induction Annealing Springs for Stress Relief
Testing was successful, with a time-to-heat of 15 seconds. This client had been using an oven but was interested in changing to induction heating.
Heating magnetic iron oxide in water for hyperthermia application
Heating magnetic iron oxide (Fe2O3) in water for hyperthermia application to determine the curve of temperature vs. time during induction heating
Brazing a steel die into a wire drawing guide
A two-turn helical coil is used for brazing the assembly. Two different bonding agents are tested for the brazing application. The first bonding agent used is braze paste. The assembly is heated to 1382 °F (750 °C) and is brazed in 45 seconds....
Hermetic Sealing a Ferrule & Fiber Optic Cable
To heat a Kovar ferrule and fiber optic cable to 297°F within 10 seconds for a soldering application, to form a hermetic seal
Annealing Copper TubingA specially designed multi-turn helical coil was used to provide the required heat to the various copper tubes.
Heating graphite susceptor for glass reflow for X-ray tubes
A two turn helical coil is used for heating. Six graphite susceptors are placed in the nitrogen atmosphere with glass discs and a stainless steel holder.
Braze a thin walled tube to a steel cap in a hydrogen atmosphere
A single turn helical coil is used to heat the quartz tube and the tube assembly. The tube assembly is held in place inside the quartz tube by a copper fixture and hydrogen is fed into the quartz tube...
Soldering a fine copper wire to an electrical connector assembly
induction heating delivered a higher quality joint, is more energy efficient than the outdated system that the client was using.
Braze two positions on a stainless steel manifold simultaneously
A dual six turn split helical coil is used to simultaneously braze the manifold...
Soldering a steel canister for sealing
Current hand-soldering process results in uneven, non-uniform joints and requires long production times. Induction delivers uniform, quality joints by generating heat within the end-plate and reservoir walls.
Annealing a Metal PlateTo heat a metal plate for an annealing application; the customer wanted to improve the heating time they were seeing with an open flame/torch.
Heating a steel mold for rubber seal vulcanization
Induction heating provides repeatable and consistent heat, quicker process time, increased production and even distribution of heating
Braze a carbide tip to steel cutting tool
A split helical coil is used to heat the carbide & circular steel cutter evenly for the brazing application. The circular steel cutter is placed in a vise and the carbide and braze shim are placed onto the tooth...
Solder Fiber Optic Cable to Ferrule & Preform
Induction heating provides rapid localized heat only where needed, repeatable, consistent results with clean, controllable joints
Heating Three Steel Parts for a Bending Application
Clients are looking to upgrade cutting-tool torch brazing process with a fast, controllable and repeatable process.
Heating a steel steam trap for calibration testing
To heat a steel steam trap to 212°F (100°C) to release steam for calibration testing
Braze a mount lead to a ferrule in a PAR light bulb assembly for automobiles
A split helical coil heats 2-3 ferrules at a time. The ferrules are filled with flux and the mount leads are placed inside the ferrules...
Soldering a steel funnel to flex spout
Induction heating delivers non-contact energy-efficient heat without flame, resulting in repeatable and consistent results
Heat a compacted litz wire bundle for stripping
A three turn helical coil is used for the wire stripping process. The litz wire bundle is placed in the coil for 3 seconds to strip the lacquer 0.75 (19mm) from the end of the bundle. The wire bundle is then scraped with a metal brush to remove the burnt lacquer...
Hermetically sealing a fiber optic cable in a kovar ferrule
Induction heating provides instant start up time, requiring very little power resources, pin point accuracy, a clean source of heat which is easily integrated into existing automated systems
Annealing a Magnetic Steel Strip
A custom-designed single position multiple-turn helical coil was built to generate the required heating for this annealing application. Initial tests were conducted to optimize the power delivered to the part.
Heating threaded area of fastener
Induction heating is localized only to the threaded area, decreases production time with a flameless process and delivers even distribution of heating
Braze electrical contacts to brass and copper bus
A five turn split helical coil is used to heat the assembly. The parts are placed 90° to the coil between the top turn and second turn with braze shims and flux.
Soldering windows to time indicator housings
Soldering soda lime glass metal edged windows to steel time
Annealing Copper Wire Connectors
To anneal electrical crimp contacts of different dimensions. The client took advantage of THE LAB’s expertise to prove out their process in a way that met their time, quality and budgetary requirements.
Heating fastener blanks for thread rolling
Induction heating provides faster cycle times and extended tool life with preheat step, fands-free heating that involves no operator skill for manufacturing
Braze a diamond carbide tip onto band saw blade
A single turn helical coil is used for this brazing process. The saw blade and diamond carbide tip are placed in the coil...
Soldering a copper chip to a silver dipped brass RF attenuator
Induction heating provides repeatable consistent results in all three areas soldered at the same time, not individually. Faster process time, increased production and even distribution of heating
Annealing a Weld Seam with Induction
The client is building a system with induction. Induction achieved the client’s speed requirements and induction’s modest footprint works well within the system.With induction you can expect the same result every time.
Simultaneously heating six wire bundles to strip varnish
Induction heating provides hands-free heating that involves no operator skill for manufacturing. A multi-position coil provides simultaneous heating for quicker production times.
Braze a stainless steel braided hose to copper elbow for flexible hosing
A two turn helical coil is used to heat the braided hose assembly. Braze rings are placed...
Annealing a Weld Seam (Steel Assembly)
Annealing with induction required 45 seconds to heat the tube to the target temperature. This application met the client's objective
Soldering electrical wires onto three connector tabs on a three position wall socket plug
Customer is currently using a soldering iron & individually touching each soldering point which is producing inconsistent results and quality issues.
Braze an end plug on a stainless steel car grill
A three turn square shaped helical coil is used to heat the end of the grill. End plugs are inserted into the grill and the assembly is inserted into the coil for 30 seconds.
Anneal copper tubes; formed tubes & pipes
Induction annealing offers the same result every time, which makes it ideal for a high volume process such as this one. The previous oxidation issue forced them to polish the handles which added a step in their manufacturing process.
Soldering 3 copper spacers to circuit board simultaneously
Induction heating delivers precise, controlled application of heat in a repeatable, non-contact, clean heating process, enabling increased production capacity and improved energy efficiency
Heating a Nitinol spring assembly for shape setting
Induction heating provides hands-free heating that involves no operator skill for manufacturing, even distribution of heating along the wire. The wire is heat treated on the winding machine, eliminating a secondary process
Brazing joint on pressurized heater connectors
Brazing a joint between a copper lug and nickel plated copper pins on a pressurized heater connector.
Annealing a stainless steel handle
The client wants to anneal a stainless steel tube while avoiding oxidation. Induction annealing offers the same result every time, copper tubes of various geometries heated to temperature in a matter of seconds, which makes it ideal for a high volume process such as this one.
Research: Heating effects on stainless steel & Tantalum discs
A three turn helical coil is used to heat the discs to 1400 °F (760°C).
Brazing steel mold for golf ball dimple insert
Induction heating provides a no-flame process with reliable, repeatable, non contact and energy efficient heat in minimal time.
Annealing brass ammunition casings
The ammunition industry has been annealing with inefficient methods which require much floor space, lack consistency, create excess inventory carry costs, and don't permit in-process inspections. Brass annealing with induction ensures each and every case is quality annealed, reducing variation and damage typically found in mass annealing processes.
Heating solutions in vials for cancer research
A four turn helical coil is used to heat the vial for 30 second intervals for five minutes with a temperature reading taken at each interval.
Heat aluminum for brazing an automotive assembly
A multi turn pancake coil is used to heat the joint between the aluminum tubing and boss. The joint heats to temperature in 1.5 minutes and the braze ring melts forming a clean brazed joint.
Annealing stainless steel tubes
Annealing with induction heated the client's parts to the desired temperature in less than three seconds. Their previously-used gas oven required twice as much heating time as the induction heating process. Induction annealing is more energy-efficient and requires less space compared to a gas oven.
Press Fitting Steel SleevesInduction is typically a faster heating method for shrink fitting than alternatives like oven heating, offering instant on/instant off heating and
localized heating, making it an efficient option.
Preheating oil drilling shaft before welding
Induction pre-heating prevents shock to shaft which eliminates cracking in the welding phase. Hands-free heating that involves no operator skill for manufacturing.
Brazing stainless steel orthodontic begg brackets
A two turn oblong helical coil is designed to heat the steel brackets which are sandwiched between the two pieces of graphite.
Shrink Fitting Steel Pipe Assemblies
A specially designed multiple-turn helical coil was used to provide the required heat for the shrink fitting application
Sintering copper powder to a stainless steel shaft
A four-turn helical coil is used to heat the assembly for five minutes. This provides slow, even heat for good penetration through the shell into the powder.
Brazing automotive tube assemblies
A four turn split helical coil is used to heat the steel assembly to 1400°F (760°C) for 85 seconds. The coil design allows for the steel fitting to expand away from the steel tube which allows braze to flow through the joint.
Shrink Fitting a Steel Part into the Casing
A specially designed multiple turn internal helical coil was used to provide the heat to the various steel parts.
Bonding a Gasket to a Sombrero Nut
A multi-turn pancake coil is used to preheat the nut. It is then transported to the next station where it is pressed onto a gasket for bonding
Brazing carbide teeth to steel pipe jaw section
Induction heating provides hands-free heating that involves no operator skill for manufacturing, consistent, repeatable aesthetically pleasing brazes with even distribution of heating
Annealing stainless steel tubing
Looking to replace an inefficient oven process, a stainless steel tube is heated in just 30 seconds, improving efficiency for this application. A custom-designed single position multi-turn helical coil was built to generate the required heating for this induction annealing application
Soldering Electrical Flex Circuits
To heat multiple joints on flex circuit strips to 180-200°F within seven seconds for a soldering application.
Shrink Fitting Magnetic Steel Pistons
Using induction for shrink-fitting magnetic steel pistons onto a chrome shaft; the client was using an unreliable handheld induction system and wanted a higher quality induction shrink-fitting solution.
Heating a motor prior to adding an injection molded part
Induction heating enables quicker process times with increased production rates versus a gas-fired oven. Ovens require long heat-up and cool-down times
Braze a refrigeration tube coil assembly
Induction heating provides the ability to direct heat only to the required zone, coil geometry which allows for easy loading and unloading of finished parts and the ability of coil to be used with water bath process allows for stability of the o-ring
Soldering a Radio AntennaTo heat a coaxial antenna assembly to 600°F within 2 seconds for a soldering application. The goal to improve on an existing procedure with a soldering iron which required 10 to 15 seconds.
Heating Hammer Bits for Shrink Fitting
Shrink-fitting hammer bits with induction for the insertion of carbide buttons; the end product is a drilling tool for the oil and gas industry.
Induction Bonding Metal to Plastic for Dental Tools
To prepare for induction bonding, the plastic handle was slid onto the picks or mirror and placed inside the induction heating coil and heated
Brazing stainless steel tree injector
Induction heating provides even distribution of heating, even flow of braze alloy for an aesthetically pleasing bond and system flexibility allows for the same unit to be used for two different applications which is a cost saving.
Annealing a copper wire connector (crimp)
The client wanted to be able to anneal parts of various sizes, which was achieved with a concentrator coil. Induction annealing is a new process for the client, and Ambrell's lab expertise proved very valuable when creating the process...
Soldering Solar Flex CircuitsHeat multiple joints on solar flex circuit strips to 500°F (260°C) within ten seconds for a soldering application.
Shrink Fitting a Magnetic Steel Gear
Induction shrink-fitting with EASYHEAT takes 45 minutes to heat the sample to the required temperature. The current oven process takes over two hours.
Induction Bonding Steel Cannulas
For each size cannula, the power delivered to the part was optimized to create a bond between the cannula and its bushing, without discoloring the steel of the cannula or causing the bushing to become opaque
Bulk heating a steel part prior to application of rubber molding
To preheat two irregularly shaped steel castings to be molded and bonded with synthetic rubber
Soldering three fuse caps simultaneously
Soldering three fuse caps simultaneously to reflow lead free solder and make a joint between the fuse cap and fuse wire guide
Induction Bonding Aluminum & Carbon Fiber Coupons
To enable the process of bonding with induction, three custom-designed single position multiple-turn coils were built to generate the required heating for this application (helical, pancake and u-shaped coils).
Heat a braided cable prior to cutting
To preheat two irregularly shaped steel castings to be molded and bonded with synthetic rubber
Braze four copper bus bars together
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
Annealing steel wire for a medical application
Induction annealing achieved the targeted steel wire temperature within three seconds. Ambrell performed a free laboratory test, designed a cost efficient, in-house process and connected them with an automation partner to maximize productivity. The client now has better control over their end product.
Soldering three brass connectors in a solar panel junction box assembly
Solder three brass connectors one at a time in a solar panel junction box without affecting the components in the junction box
Bonding Steel Wire; Rubber Molding
To heat steel wire embedded in rubber molding for a bonding application in the automotive industry